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44180 Rev2 Operator Man 35c d 44a b



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                     ~ I. RII
          . It             .. ~
         ..,                                            '~~
    stud (this location is tagged).
D 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 COOLING SYSTEM section of this manual.
D Visually examine the engine. Look for loose or missing
    parts, disconnected wires, and unattached hoses. Check                                  OIL FILL CAP
    the threaded connections and engine attachments.
D Make certain there is proper ventilation around the
    engine. An ample supply is necessary for proper engine
    performance.
D   Make sure the mounting installation is secure.
D   Ensure the propeller shaft is securely attached to the
    transmission.
D   Open the through-hull and prime the raw water intake
    strainer. Inspect the raw water supply.




                                                          Engines & Generators

                                                                   8
                                   STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM                                                        5. Should the engine not start when the START button is
                                                                              depressed for 10 to 20 seconds, release both buttons and
The 44N35Cdiesel engine has a 12V DC electric starter.
                                                                              wait 30 seconds; repeat the procedure above and preheat
The start circuitry is designed so that the PREHEAT button                    longer. Never run the starter for more than 30 seconds.
must be depressed for the time specified in the preheat chart.
Then, while keeping the PREHEAT button engaged, the
START button is depressed to crank the engine.                              A    CAUTION: Prolonged cranking intervals without
Starting Procedure                                                          the engine starting can result in the engine exhaust
                                                                            system filling with raw water. This may happen because
1. Place the transmission in neutral and advance the throttle
    control to slightly open.                                               the pump is pumping raw water through the raw water
                                                                            cooling system during cranking. This raw water can
                                                                            enter the engine's cylinders by way of the exhaust
     A CAUTION: Make certain the transmission is                            manifold once the exhaust system fills. Prevent this
     in neutral. Starting in gear could result in serious                   from happening by closing the raw water supply
     damage to your transmission, your boat, and                            through-hull shutoff, draining the exhaust muffler, and
     vessels nearby.                                                        correcting the cause of the excessive engine cranking.
                                                                            Engine damage resulting from raw water entry is not a
2. Tum the KEY SWITCH to the ON position (2 o'clock).
                                                                            warrantable issue; the owner/operator should keep this
3. Depress the PREHEAT switch. The voltrrieter, panel
                                                                            in mind.
   lights, gauges, meters and fuel solenoid will be activated.
   The PREHEAT switch should be depressed in accor-
   dance with the following chart:                                         6. Once the engine starts, check the instruments for proper
                      TemperatureJPreheat                                     oil pressure and battery charging voltage.

     Atmospheric Temperature             Preheating Time                      NOTE: Never attempt to engage the starter while the
        41F(5C) or higher            Approx. 10 seconds
                                                                               engine is running.
     41F(5C) to 23F (-5C)          Approx. 15 seconds                     NOTE: Some unstable running may occur in a cold
        23F(-5C) or lower             Approx. 20 seconds                    engine. Depressing the PREHEAT button for 10- 15
      Limit of continuous use       30 seconds before cranking                second intervals will help stabilize the engine rpm until
                                                                              the engine operating temperature reaches 170 -190F
NOTE: The START button will not energize unless the PRE-                      (77 - 88C) and a propeller load is applied to the engine.
HEAT button is depressed. Depressing the PREHEAT button                       When the engine is running and the PREHEAT button is
activates the glow plugs in the cylinder head so use the PRE-                 depressed, a charging load on the DC alternator will be
HEAT intermittently to avoid overheating the glow plugs.                      discernible.
4. While still depressing the PREHEAT button, depress the
   START button. This will engage the starter solenoid.
                                                                           Starting Under Cold Conditions
   Upon engine starting, release the START switch. Do not                  Make sure the lubricating oil is appropriate for the prevailing
   release the PREHEAT switch until the oil pressure reaches               temperature. Use oil with an API Specification of CF or CG-4,
   5 - 10 psi. Then as long as the high water temperature and              SAE 30, lOW-30, or 15W-40.
   low oil pressure protective circuits do not activate, the engine        The battery should be fully charged to minimize voltage drop.
   will remain energized and continue to run.                              Use a sufficient amount of preheat to aid in starting. See the
                                                                           Temperature/Preheat chart elsewhere in this section.

                                                                           Stopping Procedure
NOTE: When starting:                                                       To stop the engine, bring the throttle to an idle position and
A voltage drop will occur                                                  place the transmission in neutral. Allow the engine to idle for
when the preheat button                                                    a few moments to stabilize temperatures. Turn the engine off
is depressed.                                                              using the stop control cable. If your engine is equipped with
                                                                           an optional fuel shut off solenoid, turn off the key switch at
                                                                           the control panel.
                                                                           NOTE: Make certain this key switch is in the OFF position
                                                                           (12 o'clock). If the key switch is left ON, the battery will
                                                                           discharge. An engine alarm buzzer is provided to warn the
                                                                           operator of this condition (key switch ON). The best method
                                                                           of preventing the battery from discharging is to remove the
                                                                           key from the key switch after stopping the engine.



                                                                 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 engine's
   with a red warning light.                                            oil gallery. This switch's sensor monitors the engine's oil
   The Admiral Control Panel uses a voltmeter to monitor the            pressure. Should the engine's oil pressure fall to 5 - 10 psi
   performance of the alternator.                                       (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.

   COOLANT TEMPERATURE SWITCH
   A coolant temperature switch is located on the thermostat
   housing. This switch will activate a continuous alarm if the
   coolant's operating temperature reaches approximately 210 0 P
   (99C).        .
                                                                             DlL PRESSURE SWITCH




                                                                             /
                                                                         /


                                                                                                          SENDOR
                                                                        ENGINE CIRCUIT BREAKER
COOLANT                                                                 The DC harness on the engine is protected by an engine-
TEMPERATURE                                                             mounted manual reset circuit breaker (20 amps DC).
SWITCH                                                                  Excessive current draw or electrical overload anywhere in
                                                                        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
   SENDORS                                                              engine.
   The coolant temperature and oil pressure sendors are not
   installed in the 44N35C engines as standard equipment.
   Both sendors are, however, included in the Admiral
   Instrument Panel Kit.
   These sendors (with connecting gauges) can be added as
   accessories to either engine at any time and are easily
   installed to the prewired engine.




                                                              Engines & Generators

                                                                   10
                                      ENGINE BREAK-IN PROCEDURE
DESCRIPTION                                                            3. While using the vessel, run the engine at various engine
                                                                          speeds for the first 25 hours. Avoid prolonged periods of
Although your engine has experienced a minimum of one
                                                                          idling.
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-            4. Avoid rapid acceleration, especially with a cold engine.
ated properly, a break-in time is required. The service life of        S. Use caution not to overload the engine. The presence of a
your engine is dependent upon how the engine is operated                  grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use.                          reach its full rated speed are signs of an overload.
Breaking-in a new engine basically involves seating the pis-           6. During the next 25 hours, the engine may be operated at
ton rings to the cylinder walls. Excessive oil consumption                varying engine speeds, with short runs at full rated rpm.
and smoky operation indicate that the cylinder walls are                  Avoid prolonged idling during this break-in period.
scored, which is caused by overloading the engine during the
break-in period.                                                       CHECK LIST
Your new engine requires approximately 50 hours of initial             o   Monitor the control panel gauges.
conditioning operation to break in each moving part in order           o   Check for leaks of fuel and engine oil.
to maximize the performance and service life of the engine.            o   Check for abnormal noise such as knocking, friction,
Perform this conditioning carefully, keeping in mind the fol-              vibration and blow-back sounds.
lowing:
                                                                       o   Confirm exhaust smoke:
1. 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.
2. Allow the engine to warm up (preferably by running at
                                                                       NOTE: See the TRANSMISSION section of this manual for
                                                                       break-in 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 OPERATION
CHECK LIST                                                             STARTING THE ENGINE
Follow this check list each day before starting your engine.           NOTE: See STARTING/STOPPING PROCEDURE in this
D Record the hounneter reading in your log (engine hours               manual for more detailed instructions.
    relate to the maintenance schedule.)
                                                                       1. Put the transmission in neutral, throttle advanced.
D Visually inspect the engine for fuel, oil, or water leaks.
D Check the oil level (dipstick).                                         NOTE: Hydraulically operated transmissions have a
                                                                          neutral safety switch through which the starter solenoid
D Check the coolant level in the coolant recovery tank.                   energizing circuit passes. This switch is open when the
    Periodically check the manifold coolant level.                        transmission is in gear so the starter solenoid will not
D Check the transmission fluid level.                                     energize.
D Check your diesel fuel supply.                                       2. Tum the KEY to the ON position (2 o'clock).
D Look for clean fuel in the fuel filter/water separator trans-        3. Depress PREHEAT (10 to 15 seconds).
    parent bowl.
                                                                       4. While pressing PREHEAT, push START. As the engine
D   Check for loose wires at the alternator and make sure its             fires, release START.
    mounting is secure.
                                                                       S. Hold PREHEAT until the oil pressure reaches 15 psi
D   Check the starting batteries (weekly).                                and/or the alarm shuts off.
D   Check drive belts for wear and proper tension (weekly).
                                                                          NOTE: Some unstable running may occur in a cold
D Check the raw water pump to make sure its mounting is                   engine. This condition should abate as normal operating
    secure.                                                               temperature is reached and loads are applied.
                                                                          NOTE: Should the engine fail to start, wait 30 seconds,
                                                                          then repeat the above procedure, and PREHEAT longer.
                                                                       6. Allow a few minutes for the engine to warm at a com-
                                                                          fortable rpm (approximately 1000 rpm), then reduce the
                                                                          rpm, and get underway.




                                                          Engines & Generators

                                                                  12
                                             MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hourrneter or                  A WARNING: Never attempt to perform any service
record your engine hours by running time.                                     while the engine is running. Wear the proper safety
NOTE: Many of the following maintenance procedures are                        equipment such as goggles and gloves, and use the
simple but others are more difficult and may require the                      correct tools for each job. Disconnect the battery
expert knowledge of a service mechanic.                                       terminals when servicing any of the engine's DC
                                                                              electrical equipment.


        SCHEDULED              CHECK                 HOURS OF OPERATION
                               EACH                                                                      MAINTENANCE DESCRIPTION
       MAINTENANCE
                                DAY     50     100     250     500    750 1000 1250
 Fuel Supply                    0                                                             Diesel No.2 rating of 45 cetane or higher.
 Fuel/Water Separator           0                                                             Check for water and dirt in fuel (drain/replace filter
                                                                                              if necessary).
 Engine Oil level               0                                                             Oil level should indicate between MAX. and LOW on
                                                                                              dipstick.
 Coolant level                  0                                                             Check at recovery tank; if empty, check at manifold.
                                                                                              Add coolant if needed.
 Transmission Fluid level       0                                                             Fluid level should indicate between MAX and LOW
                                                                                              on dipstick.
 Drive Belts                    0                                                             Inspect for proper tension (3/8" to 1/2" deflection)
                               weekly                                                         and adjust if needed. Check belt edges for wear.
 Visual Inspection of Engine    0       NOTE: Keep engine surface clean. Dirt and             Check for fuel, oil and water leaks. Inspect wiring
                                        oil will inhibit the engine's ability to remain       and electrical connections. Keep bolts & nuts tight.
                                        cool.                                                 Check for loose belt tension.
 Fuel Filter                            0               0      0       0       0          0   Change at 50 hours then every 250 hours.
 Starting Batteries             0                                                             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                  0       0       0      0       0       0          0   Initial engine oil & filter change at 50 hours, then
                                                                                              change both every 100 hours.
 Heat Exchanger Zinc Anode              0       0       0      0       0       0          0   Inspect zinc anode, replace if needed. Clear the heat
                                                                                              exchanger end of zinc anode debris.
 Fuel/Water Separator                           0       0      0       0       0          0   Change filter every 200 hours.
 Exhaust System                         0               0              0                  0   Initial check at 50 hours, then every 250 hours.
                                                                                              Inspect for leaks. Check anti-siphon valve opera-
                                                                                              tion. Check the exhaust elbow for carbon and/or
                                                                                              corrosion buildup on inside passages; clean and
                                                                                              replace as necessary. Check that all connections are
                                                                                              tig ht. Check casti ng integ rity.
 Engine Hoses                                   0       0      0       0       0          0   Hose should be hard & tight. Replace if soft or
                                                                                              spongy. Check and tighten all hose clamps.
 Throttle and Transmission              0               0              0                  0   Check for loose fittings, cotter pins, etc.
 Control Cable                                                                                Lubricate with WD-40 or equivalent.
 Adjust Engine Idle Speed               0                                                     Adjust to 750 - 1000 rpm
 Raw Water Pump                                         0              0                  0   Remove the pump cover and inspect the impeller,
                                                                                              gasket, cam and cover for wear. Check the bearings
                                                                                              and seals (the shaft can turn, but not wobble).
                                                                                              Lubricate when reassembling.
                                                                                                                                            ( 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                                             D                 D    Drain. flush. and refill cooling system with appro-
                                                                                   priate antifreeze mix.
 DC Alternator                                        D          D            D    Check DC charge from alternator. Check mounting
                                                                                   bracket; tighten electrical connections.
 Air Intake Filter                            D       D     D    D       D    D    Clean every 100 operating hours.
 Transmission Oil Cooler                                                 D         Remove; have professionally cleaned and pressure
                                                                                   tested.
 Engine Transmission                                                     D         Chattering at idle and low rpms is an indication
 Damper Plate                                                                      of damper plate wear. Remove and replace.
 *Fuellnjectors                                                  D                 Check and adjust injection opening pressure and
                                                                                   spray condition (see ENGINE ADJUSTMENTS).
 *Starter Motor                                             D                 D    Check solenoid and motor for corrosion. Remove
                                                                                   and lubricate. Clean and lubricate the starter motor
                                                                                   pinion drive.
 *Preheat Circuit                                           D                 D    Check operation of preheat solenoid. Remove and
                                                                                   clean glow plugs. Reinstall with anti-seize
                                                                                   compound on threads.
 *Engine Cylinder                                           D                 D    Check compression pressure and timing (see Engine
  Compression                                                                      Adjustments).
 *Adjust the Valve Clearances           D                   D            D         Adjust Valve Clearances (see ENGINE
                                                                                   ADJUSTMENTS).
 *Heat Exchanger                                                         D         Remove. have professionally cleaned and pressure
                                                                                   tested.
 Lubricate Panel Key Switch                   D       D     D    D       D    D    At first 100 hours. then each year at winterizing.
 with "Lockeze"
 Transmission                           D             D     D    D       D    D    Initial fluid change at 25 hours. then every
 Fluid                                                                             300 hours or at winterizing.




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




                                                            Engines & Generators

                                                                 14
                                                 COOLING SYSTEM

DESCRIPTION                                                           When the engine is started cold, external coolant flow is pre-
                                                                      vented by the closed thermostat (although some coolant flow
Westerbeke marine diesel engines are designed and equipped
                                                                      is bypassed around the thermostat to prevent the exhaust
for fresh water cooling. Heat produced in the engine by com-
                                                                      manifold from overheating). As the engine warms up, the
bustion and friction is transferred to fresh water coolant
                                                                      thermostat gradually opens, allowing full flow of the engine's
which circulates throughout the engine. This circulating fresh
                                                                      coolant to flow unrestricted to the external portion of the
water coolant cools the engine block, its internal moving
                                                                      cooling system.
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means of a heat          Coolant Recovery Tank
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while             A coolant recovery tank allows for engine coolant expansion
fresh water coolant flows around the tubes; engine heat trans-        and contraction during engine operation, without any signifi-
ferred to the fresh water coolant is conducted through the            cant loss of coolant and without introducing air into the cool-
tube walls to the raw water which is then pumped into the             ing system. This tank should be located at or above the
exhaust system where finally it is discharged overboard. In           engine manifold level and should be easily accessible.
other words, the engine is cooled by fresh water coolant, this        CHANGING COOLANT
coolant is cooled by raw water, and the raw water carries the
                                                                      The engine's coolant must be changed according to the
transferred heat overboard through the exhaust system. The
                                                                      MAINTENANCE SCHEDULE. If the coolant is allowed to
fresh water coolant and raw water circuits are independent of
                                                                      become contaminated, it can lead to overheating problems.
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.                                                      A CAUTION: Proper cooling system maintenance is
FRESH WATER COOLING CIRCUIT                                            critical; a substantial number of engine failures can be
                                                                       traced back to cooling system corrosion.
NOTE: Refer to the ENGINE COOlANT section for the rec-
ommended antifreeze and water mixture to be used as the
fresh water coolant.                                                  To drain out the old engine coolant, loosen the manifold
Fresh water coolant is pumped through the engine by a circu-          pressure cap and unfasten the drain hose as shown below.
lating pump, absorbing heat from the engine. The coolant              NOTE: The drain petcock on the heat exchanger should also
then passes through the thermostat into the manifold, to the          be used to help drain engine coolant.
heat exchanger where it is cooled, and returned to the enaine
block via the suction side of the circulating pump.
                                                                       A WARNING: Beware of the hot engine coolant.
                                                         0



                                                                        Wear protective gloves.




                    ENGINE BLOCK




                          RELEASE THE COOLANT LINE
                          FROM THE OIL COOLER TO
                          DRAIN THE COOLANT FROM
                                                                              OIL FILTER
                          THE ENGINE BLOCK




                                                         Engines & Generators

                                                                 15
                                                              COOLING SYSTEM
           Refilling the Coolant                                                   Replacing the Thermostat
           After replacing the engine block drain plug, close the heat             Remove the cap screws and disassemble the thermostat hous-
           exchanger's coolant petcock. Then pour clean, premixed                  ing as shown. When installing the new thermostat au.d gas-
           coolant into the manifold and when the coolant is visable in            ket, apply a thin coat of sealant on both sides of the gasket
           the manifold, start the engine and run it at slow idle.                 before pressirig it into place. Do not over-tighten the cap
           NOTE: Open the air-bleed petcock on the heat exchanger.                 screws.
           When a steady flow of coolant appears at the petcock, close
                                                                                   Run the engine and check for normal temperatures and that
           the petcock and fill the system until the manifold remains full.
                                                                                   there are .no leaks at the thermostat housing.
           Monitor the coolant in the manifold and add as needed. Fill
           the manifold to the filler neck and install the manifold pres-
           sure cap.
           Remove the cap on the coolant recovery tank and fill with
           coolant mix to halfway between LOW and MAX and replace
           the cap. Run the engine and observe the coolant expansion
           flow into the recovery tank.
           After checking for leaks, stop the engine and allow it to cool.
           Coolant should draw back into 'the cooling system as the
           engine coolll down. Add coolant to the recovery tank if
           needed. Cle~ up any spilled coolant:

              TO COOLANT                KEEP THE
           RECOVERY TANK                COOLANT PASSAGE
                                        CLEAR

                                                                                     THERMOSTAT                                         TEMPERATURE
                                                                                     ASSEMBLY                                           SENDOR
                                                                                                                                        [OPTIONAL]
                                         COOL4NT EXPANSION
            FROM COOLANT
            RECOVERY TANK                                  PRESSURE
                                                         /CAP
                                            ~~:;-m;;iiiiII                         RAW WATER COOLING CIRCUIT
                                                                                   The raw water flow is created by a positive displacement
                                                                                   impeller pump. This pump draws water directly from the raw
                                                                                   water source (ocean, lake, or river) through a hose to the
                                       COOLANTRETR4CnON                            water strainer. The raw water passes from the strainer
           NOTE: Periodically check the condition of the manifold                  through the raw water pump to the heat exchanger (through
           pressure cap. Ensure the upper and lower rubber seals are in            the heat exchanger tubes) where it cools the engine circulat-
           good condition. Check to ensure                                         ing fresh water coolant. The raw water is then discharged
           the vacuum valve opens and                                              into the water-injected exhaust elbow, mixing with and cool-
           closes tightly. Carry a spare                                           ing the exhaust gasses. This mixture of exhaust gas and raw
           cap. Check also to ensure the                                           water is discharged overboard by the engine's exhaust gas
           coolant passage is clear so                                             discharge pressure.
           coolant within the system is
           able to expand and contract                                             Raw Water Pump
           to and from the coolant recovery tank.                                  The raw water pump is a self-priming, rotary pump with a
                                                                                   non-ferrous housing and a neoprene impeller. The impeller
           THERMOSTAT                                                              has flexible vanes which wipe against a curved cam plate
           A thermostat, located near the manifold at the front of the             within the impeller housing, producing the pumping action.
           engine, controls the coolant temperature as the coolant contin-         On no account should this pump be run dry as water acts as a
           uously flows through the closed cooling circuit. When the               lubricant for the imp~ller. There should always be a spare
           engine is first started, the closed thermostat prevents coolant         impeller and impeller cover gasket (an impeller kit) aboard.
           from flowing (some coolant is by-passed through a hole in the           Raw water pump impeller failures occur when lubricant (raw
           thermostat to prevent the exhaust manifold from overheating).           water) is not present during engine operation. Such failures
           As ~e engine warms up, the thermostat gradually opens. The              are not warrantable, and operators are cautioned to make sure
           thermostat is accessible and can be checked, cleaned, or                raw water flow is present at start-up.
           replaced easily. Carry a spare thermostat and gasket.                   NOTE: Should a failure occur with the pump:r internal parts
                                                                                   (seals and bearings), it may be more cost efficient to pur-
                                                                                   chase a new pump and rebuild the original pump as a spare.
                                                               -.'    WESTERBEKE
                                                                       Engines & Generators

                                                                              16
Revised: February 2002
                                                      COOLING SYSTEM
     Changing the Raw Water Pump Impeller                                  NOTE: Also follow the above procedure after having run hard
     Close the raw water intake valve. Remove the pump cover               aground.
     and, with the aid of two small screwdrivers, carefully pry the        If the engine temperature gauge ever shows a higher than
     impeller out of the pump. Install the new impeller and gasket.        normal reading, the cause may be that silt, leaves or grass
     Move the blades to conform to the curved cam plate and                may have been caught up in the strainer, slowing the flow of
     push the impeller into the pump's housing. When assem-                raw water through the cooling system.
     bling, apply a thin coating of lubricant to the impeller and
     gasket. Open the raw water intake valve.

~@

1:
                                                                      STRAINER
                                                                      FILTER                                    I
                                                                                                               L~.--.
                                                                                                                f              ,


                                                                                                               ~--~
                                                                                       TYPICAL RAW WATER INTAKE STRAINER
                                                                                                 Owner Installed

                                                                           HEAT EXCHANGER
                                                                           The heat exchanger is a copper cylinder which encloses a
                                                                           number of small copper tubes. Raw water is pumped through
                                                                           the small copper tubes and the fresh water coolant from the
                                                                           engine is circulated around the copper tubes. The raw water
      A    CAUTION: If any of the vanes have broken off the                removes heat from the fresh water coolant.
      impeller, they must be found to prevent blockage in the
      cooling circuit. They often can be found in the heat
      exchanger.
                                                                                 HEAT EXCHANGER
     Raw Water Intake Strainer
     NOTE: Always install the strainer at or below the waterline so                                                                HEAT EXCHANGER
                                                                                                                                   GASKET
     the strainer will always be self-priming.
     A clean raw water intake strainer is a vital component of the
     engine's cooling system. Include a visual inspection of this
     strainer when making your periodic engine check. The water
     in the glass should be clear.                                           PETCOCK

     Perform the following maintenance after every 100 hours of
     operation:                                                                         CLEAN
                                                                                        DEBRIS
     1. Close the raw water seacock.
     2. Remove and clean the strainer filter.
                                                                                                                       ZINC
     3. Clean the glass.
                                                                                                                       ANODE
     4.   Replace the washer if necessary.
     5.   Reassemble and install the strainer.
     6.   Open the seacock.
     7.   Run the engine and check for leaks.


                                                             Engines & Generators

                                                                     17
                                                   COOLING SYSTEM
Zinc Anode                                                            If the zinc anodes need replacement, hold the hex boss into
                                                                      which the zinc anode is threaded with a wrench while loos-
~ zi~c ~o~e, or pencil, is located in the raw water cooling
                                                                      ening the anode with another wrench. This prevents the hex
CIrCUIt wIthin the heat exchanger. The purpose of having
                                                                      boss from possibly tearing off the exchanger shell. After
zinc ~odes is to sacrifice them to electrolysis action taking
                                                                      removing the zinc, note the condition of it. If the zinc is in
place In the raw water cooling circuit, thereby reducing the
                                                                      poor condition, there are probably a lot of zinc flakes within
effects of electrolysis on other components of the system.
                                                                      the exchanger. Remove the end of the heat exchanger and
The condition of the zinc anode should be checked monthly
                                                                      clean the inside of all zinc debris. Always have a spare heat
and the anode cleaned or replaced as required. Spare anodes
                                                                      exchanger end gasket in case the present one becomes dam-
should be carned on board.
                                                                      aged when removing the end cover. Replace the gasket (refer
                                                                      to your engine model's heat exchanger end gasket part num-
                                                                      ber), O-ring 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
                                                                      and pressure test the engine's heat exchanger. (A local auto-
   NEW                    REPLACE                CLEAN & REUSE        motive radiator shop should be able to clean and test the heat
                                                                      exchanger.)
                                                                      NOTE: Operating in silty and/or tropical waters may require
NOTE: Electrolysis action is the resultof each particular             that a heat exchanger cleaning be performed more often than
installation and vessel location; not that of the engine.             every 1000 hours.



                                              AIR INTAKE I SILENCER
Description
A marine diesel engine running at high speed will typically
consume more than 6,000 cubic feet of air per hour. Not only
must the engine room be well ventilated, the air flow into the
engine must be unrestricted.
                                                                                                 "'~~~~----FILTER
Air Filter                                                                                                            CARTRIDGE
The air filter cartridge prevents engine room dust and dirt
from entering the engine,


Maintenance
The filter should be cleaned every 100 operating hours. Tap
the cartridge on a flat surface to dislodge loose dirt or clean .
off with compressed air. If the cartridge is badly contaminated
or oily, replace it.




                                                            Engines & Generators

                                                                 18
                                                       FUEL SYSTEM
DIESEL FUEL                                                             FUEL FILTERS
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do           The fuel injection pump and the fuel injectors are precisely
not use kerosene or home heating fuel.                                  manufactured and they must receive clean diesel fuel, free
                                                                        from water and dirt. To ensure this flow of clean fuel, the fuel
FUEL FILTER/WATER SEPARATOR                                             must pass through at least two fuel filters, a fuel filter/water
A primary fuel filter of the water separating type must be              separator and the engine's spin-on fuel filter. Visually inspect,
installed between the fuel tank and the engine to remove                clean, and change these filters according to the maintenance
water and other contaminants from the fuel before they can              schedule in this manual.
be carried to the fuel system on the engine.
Most installers include a fuel filter/water separator with the
installation package as they are aware of the problems that              A WARNING: Shut off the fuel valve at the tank
contaminants in the fuel can cause.                                      when servicing the fuel system. Take care in catching
A typical fuel filter/water separator is illustrated below. This         any fuel that mlY spill. DO NOT allow any smoking,
is the Raycor Model 500 MA. Keep in mind that if a water                 open flames or other sources of fire near the fuel sys-
separator type filter is not installed between the fuel supply           tem when servicing. Ensure proper ventilation exists
tank and engine-mounted fuel system, any water in the fuel               when servicing the fuel system.
will affect the fuel pump, engine filter, and injection equip-
ment. The owner/operator is responsible for making certain
the fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator.




FUEL FILTER
WATER SEPERATOR
                                                                                                                                            FUEL


         ~ ~ ~'
                                                                                                                                            FILTER




FUEL   I~~~ION       PUMP        ~ .:~:~
The fuel injection pump is a very important component of
the diesel engine, requiring the utmost care in handling. The                                                                I   BOWL I
fuel injection pump has been thoroughly bench-tested and the            ENGINE, FUEL FILTER
owner-operator is cautioned not to attempt to service it. If it         Periodically check the fuel connections and the bowl for
requires servicing, remove it and take it to an authorized fuel         leakage. Clean the filter element with kerosene or diesel fuel
injection pump service facility. Do not attempt to disassem-            after the first 50 hours then follow the MAINTENANCE
ble and repair it.                                                      SCHEDULE for cleaning and replacement.
The only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for engine idle               Changing/cleaning the filter element
speed (see IDLE SPEED ADJUSTMENT under ENGINE                           1. Shut off the fuel supply.
ADJUSTMENTS).
                                                                        2. Unscrew the retainer ring that holds the filter bowl to the
FUEL LIFT PUMP                                                             housing and allow the bowl to come away from the
                                                                           housing,
Periodically check the fuel connections to and out of the
pump and make sure that no leakage is present and that the              3. Remove and replace the filter element and clean the bowl.
fittings are tight and secure. The DC ground connection at              4. Replace the sealing "0" ring and reassemble the bowl to
one of the pump's mounting bolts should be clean and well                  the housing. Thread the retainer ring on carefully so as not
secured by the mounting bolt to ensure proper pump opera-                  to cross thread. When retainer contacts the "0" ring,
tions.                                                                     tighten 114 - 1/2 turns by hand. Open the fuel supply and
When energized thru the preheat circuit, the fuel lift pump                run the engine to inspect for leaks.
will purge air from the fuel system and provide a continuous
flow of fuel as the engine is running.




                                                            Engines & Generators

                                                                   19
                                                     GLOW PLUGS
DESCRIPTION                                                          Re-install the plugs in the engine and test them again. The
                                                                     plugs should get very hot (at the terminal end) within 7 to 15
The glow plugs are wired through the preheat solenoid.
                                                                     seconds. If the plugs don't heat up quickly, check for a short
When PREHEAT is pressed at the control panel this solenoid
                                                                     circuit. When reinstalling the glow plugs, use anti-seize com-
should "click" on and the glow plug should begin to get hot.
                                                                     pound on the threads.

INSPECTION
To inspect the plug, remove the electrical terminal connec-
                                                                      A WARNING: Do not keep a glow plug on for more
tions, then unscrew or unclamp each plug from the cylinder            than 30 seconds.
head. Thoroughly clean each plug's tip and threads with a
                                                                     Glow Plug Tightening Torque   7 -11 H-Ib (1.0 -1.5 m-kg)
soft brush and cleaning solution to remove all the carbon and
oil deposits. While cleaning, examine the tip for wear and
bum erosion; if it has eroded too much, replace the plug.
                                                                                                                                 TERMINAL
TESTING                                                                                                                         ,END

An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and the
other t~ the body of the glow plug, as shown. A good glow
                                                                                              TESTING A GLOW PLUG
plug wIll have a 0.4 - 0.6 ohm resistance. This method can be
                                                                                              WITH AN OHMMETER
used with the plug in or out of the engine. You can also use
an ammeter to test the power drain (5 - 6 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.




                                                                          TESTING A GLOW PLUG
                                                                          USING A TEST LIGHT




                                                                                                                                  +




                                                '~IWESTERBEKE
                                                       I Enaines & Generators
                                                                20
                                                     ENGINE LUBRICATING OIL
        LUBRICATION DIAGRAM                                                      2. Replacing the Oil Filter. When removing the used oil fil-
                                                                                    ter, you may find it helpful and cleaner to punch a hole in
               OIL PRESSURE                                                         the upper and lower portion of the old filter to drain the
                                                                                    oil from it into a container before removing it. This helps
                                                                                    to lessen spillage. A small automotive filter wrench
                                                                                    should be helpful in removing the old oil filter.
                                                                                    NOTE: Do not punch this hole without first loosening the
       OIL PRESSURE - _ : l H I                                                     filter to make certain it can be removed.
       SWITCH
                                                                                    Place some paper towels and a plastic bag around the fil-
        OIL                                                                         ter when unscrewing it to catch any oil left in the filter.
                                                                                    (Oil or any other fluid on the engine reduces the engine's
                                                                                    cooling ability. Keep your engine clean.) Inspect the old
                                                                                    oil filter as it is removed to make sure that the rubber
                                                                                    sealing gasket comes off with the old oil filter. If this rub-
                                                                                    ber sealing gasket remains sealed against the filter
                                                                                    bracket, gently remove it.         /




      ENG'INE OIL CHANGE
      1. Draining the Oil Sump. Discharge the used oil through
         the sump drain hose (attached to the front of the engine)
         while the engine is warm. Drain the used oil completely,
         replace the hose in its bracket, and replace the end cap
         securely.
             NOTE: Thread size for the lube oil drain hose capped end
             is 114NPT.                                                                 SEALING GASKET
                                                                                    APPLY CLEAN ENGINE OIL
                                                                                    WHEN INSTALLING
                                                                                                               SPIN ON
                                                                                                             TURN ON HAND TIGHT
BMM
11/16 INCH
SOCKET
                                                                                    When installing the new oil filter element, wipe the filter
                                                                                    gasket's sealing surface on the bracket free of oil and
                                                                                    apply a thin coat of clean engine oil to the rubber gasket
                                                                                    on the new oil filter. Screw the filter onto the threaded oil
                                                                                    filter nipple on the oil filter bracket, and then tighten the
                                                                                    filter firmly by hand.
                                                                                     NOTE: Generic filters are not recommended. as the mater-

                                 ~Oll         ORAl. HOSE
                                                                                    ial standards or diameters of important items on generic
                                                                                    parts might be entirely different from genuine parts.
                                                                                    Immediately after an oil filter change and oil fill. run the
                                                                                    engine to make sure the oil pressure is normal and that
             Always observe the used oil as it is removed. A                        there are no oil leaks around the new oil filter.
             yellow/gray emulsion indicates the presence of water in
             the oil. Although this condition is rare, it does require           3. Filling the Oil Sump. Add new oil through the oil filler
             prompt attention to prevent serious damage. Call a quali-               cap on the top of the engine or through the side oil fill.
             fied mechanic should water be present in the oil. Raw                   After refilling, run the engine for a few moments while
             water present in the oil can be the result of a fault in the            checking the oil pressure. Make sure there is no leakage
             exhaust system attached to the engine and/or a siphoning                around the new oil filter or from the oil drain system, and
             of raw water through the raw water cooling circuit into                 stop the engine. Then check the quantity of oil with the
             the exhaust, filling the engine. This problem is often                  lube oil dipstick. Fill to, but not over the high mark on
             caused by the absence of an anti-siphon valve, its poor                 the dipstick, should the engine require additional oil.
             location or lack of maintenance.


                                                                     Engines & Generators

                                                                            21
                                                        OIL PRESSURE
    OIL PRESSURE                                                          TESTING OIL PRESSURE
    The engine's oil pressure, during operation, is indicated             The lubricating system is a pressure feeding system using
    by the oil pressure gauge on the instrument panel. During             an oil pump. The engine oil is drawn from the oil sump by
    normal operation, the oil pressure will range between 40 and          the oil pump, which drives the oil, under pressure, through
    60 psi (2.8 and 4.2 kglcm2).                                          the oil filter, oil cooler and various lubricating points in the
                                                                          engine. The oil then returns to the oil sump to repeat the
   NOTE: A newly started, cold engine can have an oil pressure
                                                                          continuous cycle. When the oil pressure exceeds the speci-
   reading up to 60 psi (4.2 kglcnf). A warmed engine can have
                                                                          fied pressure, the oil pushes open the relief valve in the oil
   an oil pressure reading as low as 35 psi (2.5 kglcm2). These
                                                                          pump and returns to the oil sump, keeping the oil pressure
   readings will vary depending upon the temperature of the
                                                                          within its specified range.
   engine and the rpms.
                                                                          To test the oil pressure, remove the oil pressure sender, then
                                                                          install a mechanical oil pressure gauge in it's place. After
                                                                          warming up the engine, set the engine speed at 3000 rpm
                             /
                                                                          and read the oil pressure gauge.

                                                                          Oil Pressure 35.0 Ib/ill' (3.8 kg/em') or more at 3000 rpm.
                                                                          Sender and Switch Torgue       9 -13 ft-Ib (1.2 -1.8 m - kg).
                                                 OIL LINE

                                                                          LOW OIL PRESSURE
                                                                          The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
                                                                          + 0.1 kglcm2). A gradual loss of oil pressure usually indicates
                                                                          a worn bearings. For additional information on low oil pres-
                                                                          sure readings, see the ENGINE TROUBLESHOOTING chart.
OIL PRESSURE SWITCH"




                                                                              TESTING OIL
                                                                              PRESSURE




                                              OIL PRESSURE SENDOR
                                              AS AN ACCESSORY
                                              WITH GAUGE. .. STANDARD .
                                              WITH THE ADMIRAL
                                              INSTRUMENT PANEL.
                                                                                             +

    OIL PRESSURE RELIEF VALVE
    An oil pressure relief valve is located on the engine block
    just below the injection pump. This valve opens at                                                 t-
    appoximately 50 psi [343 kpa] and maintains that pressure.                                  OIL PRESSURE




        LOCATED JUST
        UNDER THE
        FUEL INJECTION
        PUMP ON THE
        ENGINE BLOCK.

                                                   I~IWESTERBEKE
                                                            , Enaines & Generators

                                                                   22
                                           REMOTE OIL FILTER {OPTIONAL}
INSTALLATION                                                                  To install, simply remove the engine oil filter and thread on
                                                                              WESTERBEKE's remote oil filter kit as shown. Always
This popular accessory is used to relocate the engine's oil fil-              install this kit with the oil filter facing down as illustrated.
ter from the engine to a more convenient location such as an
engine room bulkhead.                                                         Contact your WESTERBEKE dealer for more information.

NOTE: Refer to ENGINE OIL CHANGE in this manualfor                            NOTE: Westerbeke is not responsible for engine failure due to
instructions on removing the oil filter.                                      incorrect installation of the Remote Oil Filter.




                                                                                                                   FASTEN SECURELY TO A BULKHEAD
APPLY A THIN COAT OF CLEAN OIL TO THE O-RING WHEN                                                                   (SCREWS ARE OWNER SUPPLIED)
INSTALLING THIS KIT. THREAD THE KIT ON, THEN HAND
TIGHTEN AN ADDITIONAL 3/4 TURN AFTER THE O-RING
CONTACTS THE BASE.




                                     NOTE THE "IN" AND "OUT" MARKINGS
                                     ON THE ADAPTER WHEN THE HOSES ARE
                                     REMOVED FOR INSTALLATION SO THEY
                                   , WILL BE RECONNECTED CORRECTLY.




                                                                                          APPLY A THIN COAT DF CLEAN OIL TO THE FIL-
                                                                                          TER GASKET WHEN INSTALLING. AFTER THE
                                                                                          FILTER CDNTACTS THE BASE, TIGHTEN IT AN
                                                                                          ADDITIONAL 3/4 TURN.
 A CAUTION: It is vital to install the oil lines cor-
 rectly. If the oil flows in the reverse direction~ the by-
 pass valve in the filter assembly will prevent the oil
 from reaching the engine causing an Intemal engine
 failure. If there is no oil pressure reading~ shutdown
 immediately and check the hose connections.




                                                                  Engines & Generators

                                                                         23
                                                                    WATER HEATER
           WATER HEATER INSTALLATIONS                                                   The pressure cap on the engine's manifold should be
                                                                                        installed aft~r the engine's cooling system is filled with
          This engine is equipped with connections for the plumbing of
                                                                                        coolant. Finish filling the cooling system from the remote
          engine coolant to transfer heat to an on-board water heater.
                                                                                        tank after the system is filled and is free of air and exhibits
          The water heater should be mounted in a convenient location
                                                                                        good coolant circulation. During engine operation, checking
          either in a high or low position in relation to the engine, so
                                                                                        the engine's coolant should be done at the remote tank and
          that the connecting hoses from the heater to the engine can
                                                                                        not at the engine manifold cap. The hose connection from the
          run in a reasonably direct line without any loops which might
                                                                                        heater to the remote expansion tank should be routed and
           trap air. -==~~~"                                                            supported so it rises continuously from the heater to the tank,
                                                                                        enabling any air in the system to rise up to the tank and out
THESE HOSES ARE                                                                         of the system.
CONNECTED IF THERE
IS NO WATER HEATER.



     \~
     ,.J
          I


      I




                                                    WATER HEATER
                                                    BELOW ENGINE




           Hoses should rise continuously from their low point at the                   NOTE: An air bleed petcock is located on the engine's
           heater to the engine so that air will rise naturally from the                heat exchanger. Open this petcock when filling the engine's
           heater to the engine. If trapped air is able to rise to the hel:\ter,        coolant system to allow air in the exchanger to escape.
           then an air bleed petcock must be installed at the higher fit-               Close tightly after all the air is removed.
           ting on the heater for bleeding air while filling the system.
          NOTE: If any portion of the heating circuit rises above the
          engine's own pressure cap, then a pressurized (aluminum)
          remote expansion tank (Kit #024177) must be installed in the
          circuit to become the highest point. Tee the remote expansion
          tank into the heater circuit, choosing the higher of the two
          connections for the return. Tee at the heater, and plumb a
          single line up to the tank's location and the other back to the
          engine's return. Install the remote expansion tank in a conve-
          nient location so the coolant level can easily be checked. The
           remote expansion tank will now serve as a check and system
          fill point. The plastic coolant recovery tank is not used when
          the remote expansion tank kit is installed, since this tank
          serves the same function. Remove and store the plastic
           recovery tank if it has been already installed.




                                                                           Engines & Generators

                                                                                   24
                                                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 the battery 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 (Ie's), 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;
     #14   GRAY==~=*-_ _
                                                                                   continue with Steps 3 through 8.

                                                                                                            mID
#14 PINK~~~~~~~
#14 BLUE=
                                                                                       MULTIMETER
                                                                                                            G
                                                                                                            COM




                                               SEE WIRING DIAGRAM
                                               FOR WIRE CONNECTIONS
                                               TO OPTIONAL ALTERNATORS.

  ALTERNATOR TROUBLESHOOTING                                                  TESTING THE STARTING
                                                                              BATTERY/ALTERNATOR
                                                                              (ENGINE RUNNING)
   A    WARNING: A failed alternator can become very .
   hot. Do not touch until the alternator has cooled down.                                              -= GROUND
  Use this troubleshooting 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 battery's charging circuit and not with the alterna-
                                                                            S. 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.
                                                                                                             0~--MULTIMETER
                                                                                                             COM




   A    WARNING: When testing with a multimeter:
   DC ~nd 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
                                                                          TESTING THE
   before performing DC testing. No AC tests should be                    ALTERNATOR VOLTAGE
   made without a proper knowledge of AC circuits.                        (IGNITION ON - ENGINE OFF)




                                                                Engines & Generators                     -= GROUND
                                                                       25
                                             DC ELECTRICAL SYSTEM
7. 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.




                                                                                MUlTIMETE".   G
                                                                                              COM




        TESTING THE STARTING
        BATTERYIALTERNATOR                                ENGINE
        (ENGINE RUNNING)                        -c==-.... GROUND

8. Start the engine again. Check the voltage between the
   alternator output and ground.                                                                               ,SERVICE BATTERY
   The voltage reading for a properly operating alternator
   should be between 13.5 and 14.5 volts. If your alternator                     GROUND                     TESTING THE SERVICE
   is over- or under-charging, have it repaired at a reliable
                                                                                                            BATTERY (ENGINE RUNNING)
   service facility.
    NOTE: Before removing the alternator for repair, use a
    voltmeter to ensure that 12 volts DC excitation is present
    at the EXC terminal if the previous test showed only bat-              A CAUTION: To avoid damaging the altemator diodes,
    tery voltage at the B output terminal.                                             a
                                                                           do not use high voltage tester (i.e. a megger) when
                                                                           performing tests on the altemator charging circuit.
    If 12 volts is not present at the EXC terminal, trace the
    wiring and lookfor breaks and poor connections.

12 VOLT DC CONTROL CIRCUIT                                                Battery Care
The engine has a 12 volt DC electrical control circuit that is            Review the manufacturer's recommendations and then
shown on the wiring diagrams that follow. Refer to these                  establish a systematic maintenance schedule for your
diagrams when troubleshooting or when servicing the DC                    engine's starting batteries and house batteries.
electrical system.                                                        o Monitor your voltmeter for proper charging during
                                                                              engine operation.                         '
 A     CAUTION: To avoid damage to the battery charging                   o Check the electrolyte level and specific gravity with a
                                                                              hydrometer.
  circuit, never shut off the engine battery switch while
 .the engine is running. Shut off the engine battery Switch,              o   Use only distilled water to bring electrolytes to a proper
                                                                              level.
  however, to avoid electrical shorts when working on the
  engine's electrical circuit.
                                                                          o Make certain that battery cable connections are clean and
                                                                              tight to the battery posts (and to your engine).
BATTERY                                                                   o   Keep your batteries clean and free of corrosion.
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 - 900 Cold
Cranking Amps (CCA).
                                                                            A WARNING: Sulfuric acid In lead batteries can
                                                                              caUSII severe burns on skin and damage clothing. Wear
                                                                              protective gear.



                                                             Engines & Generators

                                                                     26
                                 MARINE ENGINE
                               WIRING DIAGRAM #39144




        SEE NOTE   '~'
                   I
                   I
                          I

                   I   ...I




                                                                  =                                    LIFT PUMPS
                                                                  ~


                                                                  ~   : ::r----------------...I
NOTE: An on-off switch
                                                                  ;   ;   ;
should be installed in this        $I
circuit to disconnect the
starter from the battery in
an emergency and when
leaving the boat. Twelve
                                                              P2~'
                                                               ... . .
                                                                     -.-
volt engine starters                                                  p
typically draw 200 to 300                                             +       ALARM    ADMIRAL
amps when cranking. A
                                                                      C       BUZZER
                                                                                       PANEL
switch with a continuous
rating of 175 amps at 12
VDC will normally serve
this function, but a switch
must never be used to
 "make" the starter circuit.




                                             "0 AED



                                   PI


                                                                                       CAPTAIN
                                        o
                                        >
                                                                                       PANEL




                   r--

                                                        ....
                                                        ALT
                                                                                                        "l




                                                                                          T""""""'"
                                                        ....
                                                        GP




                   l~~~~~~~~~~~~~~!'!1!L'~~~~~~~~~~~~~~:;~ ~
                                        11& elK
                                        ',e BL.K
                                        .,. slIe
                                                                                       ___        -----,l




                                            Engines & Generators

                                                   27                                                        Revised December 2002
                                                         MARINE ENGINE
                                                WIRING SCHEMATIC #39144
~   12 VDC    START
               SOL.               SURfER                                                       NOTES:
              r--,                                                                                   THIS PRODUCT IS PRQTI:.CTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
~------~~r71------~Mr-------------.                                                                  STARTER    ExCESSIVE CURRENT WilL CAUSE THE BREAKER TO TRIP AND THE ENGINE Will
                                                                                                     SHUT DCWN.   THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL. WIRING, AND
                                                                              ------1                ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER.
          r_--~~r_----------------------~                                               I      2.    AN QN'OFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
                                                                                                      DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT.   A SWITCH
                                                                                                    'WITH A CONTINUOUS RATING OF 175 AMPS,   AT 12 voe Will SERVE THIS FUNCTION.   THI$
                                                                                                      SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT

                                                                                                     THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD BE         INSULATED.       CAPTAIN PANEL ONLY,
                                                                                               4     THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD I3E        INSULATED,       ADMIRAL PANEL ONLY,




                                                   LIFT PUMP
                                                                                                                                       MITSU81SHI          50 AMP ALT


                                                FUEL            'lfH[N
                  r-+-+_+-____--*"S~ 'B-IJ.!.C~                          _
                                            O.P.
                                           SENDER




                                                                                                                                 #1



                                                                                                                                 #14 GRA

                                                                                                                   PRESTOLITE\LEECE-NEVILLE 90 AMP.                  ALT.




BAT                                         TACHOMETER
                                                                             ADMIRAL
    KEY                       ,--+--+___s,,(       GNO
                                                                             PANEL                                                               ",OUltO

    sw.
IG'
                                                                                                                                                  AC TA,
                                                                                                               SATTUY 
                                                                                                                                                 .14 eRtl
                                                                                                                U RED
                                            VOL TMETER                          NOTE:
                                            +          GNI)                     WIRE FOR 6ATTERY ATTATCHMENT WILL NEED
                      o   ALARM                                                 TO BE UPGRADED TO AN 8 GAUGE FROM 10 GAUGE     '--=;-0;;;;---'
                      +




                                                       O.P.
                                                       GAUGE
                                                       GNO




                                                                                                                  PRESTOllTE 72 AMP                          ALI

                                                                                                              # 14 8RN
                                                                             CAPTAIN
                                                                             PANEL
                                                         LAMP                                                 # 14 GRA
                                                         TEST
                                                          sw.




                                                                                                              #14 PINK



              +                                                                                             #14 LT.   BL


                                    51 AMP              ALTERNATOR
                                    STANDARD ALTERNATOR ON. THE                                               UNIVERSAL PROPULSION
                                    638 I:!l. 63C I:!l. liB I:!l. 828           :or.                        PRESTOLlTE 51 AMP ALL
                                    1088 D. & 108CD.

                                                                                                                     ALE CONNECTOR
                                                                                                                    ON THIS SIDE



                                                                                                    "~~r-'-'R""r=~;:::==========;1
                                                                                            ---\T"CH)~                                RED




                                                                                                                 OPT IONAl ALTERNATORS 
                                                                                                                   135A.   160A, liOA. LESTEK ALTERNATORS
                                                                                               "v'''-L~~H_.M..~e_ 0:       63C n: 718 II IlZ8J;b 198ft XI      !.. 10llC   '.i:I 0HL,V __




                                                                             Engines & Generators
                                                                                                                                                               Revised December 2002
                                                                                  28
                                                           MARINE ENGINE
                                                   WIRING SCHEMATIC #200360
                                                       [CATALINA YACHTS]

                                                                   STARTER
   +         12 VDC                                               SOLENOID                                     STARTER                                         -
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                                                                  SOLENOID
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                                                                                                      OUTPUT
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                                                                                                                                       SWITCH

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TO THE 'B'       TO THE   TO THE'S'           TO THE 'I'   TO THE 't'   TO THE 'P'   TO THE'S'   TO THE'S'          TO THE 'c'                      TO THE TACH
 TERM. OF         START    TERM. OF            TERM. OF      TERM. OF     TERM. OF    TERM. OF    TERM. OF            TERM. OF                         GROUND _'--
 KETSWITCH       SWITCH    KETSWITCH           KEYSWITCH    THE ALARM    THE ALARM    THE TACH   W. T. GUAGE         THE ALARM
                                                              BUZZER       BUZZER                                      BUZZER




                                                        1-.'IWESTERBEKE
                                                                 Enqines & Generators

                                                                          29
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                                                         114 GRH                                                                      n      Z
                        TO THE TACHOMETER GROUND
                                                                                                                                     ;!:i   :a:-
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               TO THE 'B' TERM. OF KEYSWITCH
               TO THE'S' TERM. OF KEYSWITCH
                                                         110 RED

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                                    '"    Ii
                                              ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems                   NOTE: The engine s electrical system is protected by a 20
relating to engine service, the probable causes of these prob-                   ampere manual reset circuit breaker located on a bracket at
lems, and the recommendations to overcome these problems.                        the back of the engine. The preheat solenoid is mounted on
                                                                                 the same bracket.
               Problem                              Probable Cause                                        Verification}Remedy
 No panel indications; fuel solenoid       1. Battery switch not on.                     1. Check switch and/or battery connections.
 or fuel pump is not working (key switch
 is on and PREHEAT button is depressed).   2. 20-amp circuit breaker tripped.            2. Reset breaker, if breaker trips again, check preheat solenoid
                                                                                            circuit and check circuit for shorts to ground.
                                           3. 10-amp 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 filters 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 can't be stopped.                  1. Faulty DC altemator.                       1. Remove Exc. connection at alternator; repair alternator.
                                           2. Disconnect fuel shut-off cable.            2. Check connection at shut-off lever. Pull lever back to close
                                                                                            off the fuel.
                                           3. Fuel run solenoid will not de-energize.    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 switch.
                                           2. High resistance leak to ground.            2. Check wiring. Insert sensitive (0 - .25 amp) meter in battery
                                                                                            lines. (Do not start engine.) Remove connections and 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 alternator. See
                                              (tachometer not operating).                   DC ELECTRICAL SYSTEM/ALTERNATOR.
 Battery not charging                      1. DC charge circuit faulty.                  1. Perform DC voltage check of generator charging circuit. See
                                                                                             Testing the Battery Charging Circuit.
                                           2. Alternator drive.                          2. Check drive belt tension; alternator should turn freely. Check
                                                                                            for loose connections. Check output with voltmeter. Ensure 12
                                                                                            volts are present at the Exc. terminal.

                                                                                                                                                (continued)
                                                                                                                                                        ~




                                                                      Engines & Generators

                                                                            31
                                         ENGINE TROUBLESHOOTING
              Problem                           Probable Cause                                        VerificationJRemedy
 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 and/or 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 tank(s); change filters and
                                                                                       bleed fuel system.
                                      7. Air intake obstruction.                    7. Check air intake filter cartridge.
 Engine overheats/shuts 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 - tighten/replace.
                                                                                    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 burn incomplete due to high back-pressure in exhaust or
                                                                                        insufficient air for proper combustion (check for restrictions in
                                                                                        exhaust system; check air intake).
                                                                                    3b. Improperly timed injectors or valves, or poor compression.
                                                                                    3c. Lack of air - check air intake and air filter. Check for proper
                                                                                        ventilation.
                                                                                    3d. Overload.

                           TROUBLESHOOTING COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated               If both of the above gauge tests are positive, the gauge is
by the gauge when the instrument panel is energized, the first              undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition (B+)                  conductor from the sender to the gauge or with the sender.
and the Negative (B-) terminals of the gauge.                               If either of the above gauge tests are negative, the gauge is
Assuming that there is 12 volts as required, leave the                      probably defective and should be replaced.
instrument panel energized and perform the following steps:                 Assuming the gauge is OK, check the conductor from the
1. 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 the
2. 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

                                                                      32
                                                      TACHOMETER
TACHOMETER/HOUR METER                                                 NOTE: Current model tachometers use a coarse adjustment
The tachometerlhour meter used in propulsion engine instru-           dial to set the tachometer to the crankshaft pulley rpms. The
ment panels contains two separate electrical circuits with a          calibrating screw is then used for fine tuning.
common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the (+) terminal
on the back'ofthe instrument.
The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8                                                                     ) TERMINAL
volts DC.
The following are procedures to follow when troubleshoot-
ing a fault in either of the two circuits in a tachometerlhour                                                             (-) TERMINAL
meter.
                                                                                                                           INP
Hour meter Inoperative                                                                                                AC VOLTAGE
Check for the proper DC voltage between (+) and (-)
terminals.                                                            IDLE SPEED ADJUSTMENT
1. Voltage present - meter is defective - repair or replace.
                                                                      & TACHOMETER CHECK (New Installation)
2. 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 the
Tachometer Inoperative                                                engine ~ rpm This calibration should be checked in all new
Check for the proper AC voltage between tachometer input              installations.
terminal and (-) terminal with the engine running.
                                                                       1. Warm up the engine to normal operating temperature.
1. 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 the
2. 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 engine.
3. 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 panel
4. Check electrical connections from tachometer input ter-                tachometer reading. Adjust the tachometer in the panel by
   minal to alternator connection.                                        using the instrument coarse adjustment to calibrate the
                                                                          instrument reading to the closest R.P.M. that the photo tach
Tachometer Sticking                                                       is showing. Then use the fine calibration adjustment to
1. Check for proper AC voltage between "tach inp." termi-                 bring the instrument to the exact reading as the photo tach.
   nal and (-) terminal.                                               4. Adjust the idle speed if the engine speed is not within the
2. Check for good ground connection between meter (-) ter-                specified value.
   minal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt.
Tachometer Inaccurate
               --..
a. With a hand-held tach on the front of the crankshaft pul-
   ley retaining nut or with a strobe-type tach, read the front
   crankshaft pulley rpm at idle,
b. 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 the hand tach. (Verify the rpm
   at idle and at high speed rpm,). (Adjust the tach as
   needed.)




                                                             Engines & Generators

                                                                  33
                                              ENGINE ADJUSTMENTS
ADJUSTING THE IDLE SPEED                                               DRIVE BELT ADJUSTMENT
1. Loosen the locknut on the idle adjustment bolt on the               Proper inspection, service and maintenance of the drive belts
   fuel injection pump.                                                is important for the efficient operation of your engine (see
2. Adjust the bolt so that the throttle control lever will hold        Drive Belts under MAINTENANCE SCHEDULE).
   the engine at a quiet idle. [750 - 1000 RPM]                        Drive belts must be properly tensioned. Loose drive belts
3. Tighten the locknut.                                                will not provide proper alternator charging and will eventu-
                                                                       ally damage the alternator. Drive belts that are too tight will
4. Race the engine several times to ensure the idle speed
                                                                       pull the alternator out of alignment and/or cause the alterna-
   remains as set.                                                     tor to wear out prematurely. Excessive drive belt tension can
NOTE: Should the engine rpm be in question, verify the                 also cause rapid wear of the belt and reduce the service life
tachometer readings as shown at the instrument panel with a            of the coolant pump's bearing. A slack belt or the presence of
mechanical or strobe-type tachometer at the engine crank-              oil on the belt can cause belt slipping, resulting in high oper-
shaft. See TACHOMETER.                                                 ating temperatures and tachometer variations.
                                       IDLE ADJUSTMENT BOLT            The drive belt is properly adjusted if the belt can be deflected
                                                                       no less than 3/8 inch (IOrnm) and no more than 112 inch
                                                                       (12rnrn) as the belt is depressed with the thumb at the mid-
                                                                       point between the two pulleys on the longest span of the belt.
                                                                       A spare belt or belts should always be carrie
The oil capacity for the transmission is approximately 1.0
quart (1.0 liter). Check the oil level daily after the engine has
                                                                           CABLE.
been warmed and stopped. The oil level should be main-
tained at the top of the machined flat on the dipstick when
the dipstick is completely inserted into the transmission hous-                       REVERSE                                   . FORWARD
ing. Make sure the two O-ring gaskets on the dipstick are in                                                    NEUTRAL
good shape. These O-rings will keep the dipstick in place.

Change the transmission oil after the first 25 hours of engine            SHIFTING
operation and thereafter every 250 hours or once a year, min-             To shift the transmission fron NEUTRAL into FORWARD,
imum. The transmission has a 6 mm Allen Hex wrench drain                  exert a heavy push to the remote control lever. A gentle throw
plug for draining the oil. To make sure most of the oil will              may not carry enough force to actually shift the transmis-
drain from the transmission, warm the oil by running the                  sion's internal gears. A gentle throw is signalled by the trans-
engine in NEUTRAL for approximately 10 to 15 minutes.                     mission not engaging into the desired drive. Make sure the
This oil may also b~ removed by attaching a pump into the                 remote control lever is lubricated at least once each operating
dipstick opening so the oil may be sucked out. The operating              season. Shift the transmission while the engine is running at
oil temperature must not exceed 250F (120C).                            1200 rpm or below.
CONTROLS
The only controls required to operate the transmission is a                A    CAUTION: NEVER remove or loosen the two-bolt
single level remote controlled cable. The cable should be                  gear box lever cover from transmission. The position of
attached to the gear box lever using the cable bracket                     this plate and the actuating level inside of the
supplied with the unit. Both the gear box lever and the
                                                                           transmission has been finely adjusted at the factory to
remote control lever must be in the NEUTRAL position
when the cable' is attached to the gear box lever. This allows             ensure equal throw distance of internal mechanisms.
the remote cable an equal throw distance to shift the gear box             Loosening of this cover's capscrews voids the
into FORWARD or into REVERSE from the NEUTRAL                              transmission warranty.
position without running out of cable. Allow approximately
1-112 inches of cable throw from the NEUTRAL position on
the transmission's gear box lever to each of the two drive
positions.




                                                  I"""""WESTERBEKE
                                                          , Enaines & Generators

                                                                     37                                                   Revised October 2001
                                                 J.S. AND B.W. TRANSMISSIONS
       SAILING OPERATION                                                           SERVICE
       The transmission should be left in its NEUTRAL position                     If any seal on the transmission shows signs of leaking, have
       while sailing. Leaving the transmission in NEUTRAL while                    the transmission looked at by a qualified WESTERBEKE
       sailing alleviates unnecessary drag on the vessel because the               dealer. This problem, especially concerning the rear seal, is
       propeller is able to freewheel (spin). However, if the trans-               often contributed to an improper alignment of the
       mission is left in its FORWARD gear while sailing, the                      transmission's coupling and the propeller shaft's coupling.
       transmission will not be damaged. (Leaving the transmission                 Disassembly of the transmission in the field is not recom-
       in NEUTRAL is just good sailing practice.)                                  mended. If an overhaul or repair is needed, the work should
                                                                                   be done by an authorized WESTERBEKE service center.
       COOLING
       The transmission is raw water-cooled. Raw water enters the                  MAINTENANCE
       transmission through a stainless steel inlet pipe located at the            Transmission maintenance is minimal. Keep the exterior
       base of the bell housing. This water helps to cool the trans-               housing clean, check the fluid level as part of your regular
       mission's lubricating oil.                                                  routine, and change the fluid every 300 operating hours.
                                                                                   Periodically inspect the transmission and the cooler for leaks
                                                                                   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).
BELL HOUSING                                                                       Lay-up/Winterize
                                                                                   Storage requires special care. Follow these procedures:
                                                                                   NOTE: This operation will usually occur when the engine raw
                                                                                   water water cooling system is properly winterized.
                                                                                   oClean up the transmission and touch-up any unpainted
                                                                                    areas (use heat resistant paint).
                                                                                ~_~ Fill the transmission with SAE 30 engine oil to prevent
                                                                       COUPLING     internal corrosion. (Extended.storage only, 12 months
                                                                                    or more).
                                                                                   oLoosen attaching hardware from the transmission output
                                                                                    flange and propeller shaft coupling flange before
                                                                                    removing the boat from the water. Seperate the flanges
                                  RAW WATER                                         and spray with lubricant.                  .
                                  COOLING                                          o   Inspect the gear shift cable, linkage, and attachments.
                                                                                       Look for corrosion of the end fittings, cracks or cuts in
                                                                                       the conduit, and bending of the actuator rods. Lubricate
         J.S. and B.W. TRANSMISSIONS                                                   all moving parts.
                                                                                   NOTE: If the transmission is to be stored for a long time
                                                                                   (tWelve months or more), it should be topped off with oil to
                                                                                   prevent internal corrosion. Reduce the oil level before putting
        J.S. AND B.W. TRANSMISSIONS SPECIFICATIONS                                 the engine back into service.
         General                 Case-hardened helical gears, with an
                                 intermediate reverse gear. Reversing out
                                 by servo double disc system.
         Gear ratio (optional)   2.47 : 1
         Propeller ShaH          Right hand - standard transmission
         (Direction of Rotation)
         Propeller               See propeller recommendations.
         Lubricating Oil         SAE 20WI20 or SAE 30 exclusively (Do
                                 not mix grades of oil or use multigrades).
                                 API, CF, CG-4, or SJ.
         Transmission Sump       1 qt. (1 liter)
         Capacity




                                                                       Engines & Generators

                                                                              38                                              Revised October 2001
                             BORG WARNER VELVET DRIVE TRANSMISSION
                                OPTIONAL TRANSMISSION /44 FOUR ONLY
                                                                       SHIFT LEVER POSITION
           OIL "U~'Ll:fll'                                             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.
BORG WARNER                                                            Shifting from one selector position to another selector posi-
VELVET DRIVE                                                           tion may be made at any time below 1000 rpm and in any
                                                                       order. Shifts should be made at the lowest practical engine
                                                                       speed. Start the engine and set the throttle at idle speed;
                                                                       allow the transmission fluid to warm up for a few minutes.
SHIPMENT
For safety reasons, the transmission is not filled with trans-         Neutral
mission fluid during shipment and the selector lever is tem-          Move the gear shift lever to the middle position. You should
porarily attached to the actuating shaft.                              feel the detent. This centers the actuating lever on the trans-
Before leaving the WESTERBEKE plant, each transmission                 mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission fluid.         completely interrupted and the output shaft of the transmis-
The residual fluid remaining in the transmission after drain-          sion does not tum.
ing acts as a preservative and provides protection against
                                                                       NOTE: Some transmissions are equipped with a neutral safety
corrosion for at least one year if properly stored.
                                                                       switch. Unless the transmission actuating lever is perfectly
TRANSMISSION FLUID                                                     aligned in neutral, the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextron III and            Forward
continue to use this fluid. During the first 25 hours of opera-        Move the gear shift lever to the forward position. You should
tion, keep a lookout for any leakage at the bell housing, out-         feel the detent. The actuating lever on the transmission is in
put shaft and transmission cooler. This fluid should be                the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300           move the boat in a forward direction.
operating hours thereafter and/or at winter lay-up.
                                                                       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
                                                                       the reverse position. The output shaft and the propeller
 and the correct size cooler is properly installed before
                                                                       should move the boat in a reverse direction (astern).
 starting the engine.
                                                                       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

                                                                  39
                        BORG WARNER VELVET DRIVE TRANSMISSION
                                                                       D Clean off the transmission and properly dispose of the
                                                                           used fluid.
                                                                       D Refill the transmission with DEXTRON III ATF. The
                                                                        quantity will vary depending on the transmission model
                                                                        and the installation angle. Fill through the dipstick hole.
                                                                      D Check the dipstick for the proper fluid level.
                                                                      D Replace the oil filler cap and dipstick. (Press the dipstick
                                                                        into place and tum clockwise until finger-tight.)
                                                                    . D Run the engine, shutdown and recheck the fluid level.
FORWARD                     NEUTRAL                REVERSE

          TRANSMISSION ACTUATING LEVER POSITIONS                        A WARNING: Never pull out the dipstick while the
                                                                        engine is running. Hot fluid will splash from the dipstick
DAILY OPERATION                                                         hole. .This could cause severe burns.
D Check the transmission fluid.
D Visually check the gear shift linkage and transmission.              Oil Capacity
D Start the engine in neutral. Allow a few minutes at idle             Approximately 2.5 quarts (2.36 liters) will fill most transmis-
   for the fluid to warm.                                              sions to the oil level fill mark on the dipstick. Many variables
   NOTE: Too Iowan 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 transmission.
D Shift into gear.
                                                                            MAKE CERTAIN THE
                                                                            RUBBER SEAL IS
 A CAUTION: Shifting gears above 1000 rpm can                               SCREWED
 cause damage to the engine damper plate. Pulling the                       TIGHT TO THE-_~!l<:
                                                                            HANDLE
 throttle back to idle when shifting gears will save wear
 on the transmission and the damper plate.
                                                                                                                          MAX
INSPECTION
D Visually check for oil leaks at the hydraulic connections.
  Check for wear on the hydraulic lines and replace if                              ---;::::=:;I*tt~tt4::--MIN
  worn.
D Lubricate the detent ball and shift cable attaclunents.
D Inspect the shift linkage.
D Inspect the transmission bolts; retorque if necessary.

 A CAUTION: Clutch failure will occur if the transmis-
 sion shift lever does not fully engage the detent ball                Oil Temperature
 positions.                                                            A maximum oil temperature of 190F (88C) is recom-
                                                                       mended. Discontinue operation anytime sump oil tempera-
CHANGING THE TRANSMISSION FLUID                                        ture exceeds 230F (110C).
After the initial 50 hour change, the transmission fluid should        PRESSURE GAUGE
be changed at every 300 operating hours thereafter or at win-
ter haul-out. However, the fluid must be changed whenever it           An optional mechanical pressure gauge can be installed at
becomes contaminated, changes color, or smells rancid.                 the control panel to constantly monitor the pressure of the
                                                                       transmission fluid. A normal reading at 2000 rpm in forward
D Remove the oil filler cap and dipstick.                              gear should indicate 95 - 120 Ib-in2 (6.7 - 8.4 kg-cm2) and be
D Remove the oil cooler return line and allow the oil to               constant.
    drain into a container.
D Reconnect the oil cooler return line.
D Use a suction pump to remove the transmission oil
     through the filler cap/dipstick hole.



                                                            Engines & Generators

                                                                  40
                        BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                            WARRANTY NOTES
Transmission maintenance is minimal. Keep the exterior                 Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular           dealer.
routine, and change the fluid every 300 operating hours.               For assistance, contact:
Periodically inspect the transmission and the cooler for leaks                Richmond and Velvet Drive
and corrosion. Make certain the air vent is clear and when                     1208 Old Norris Road
checking the fluid level look for signs of water contamination                Liberty, SC 29657
(fluid will appear as strawberry cream).                                      Tel.: (800) 583-4327
Lay-up/Winterize                                                       BORG WARNER is aware of the shock loads that can be
                                                                       placed on its gears as the result of mechanical propeller
Storage requires special care. Follow these procedures:
                                                                       operation or fully reversing of the propeller blades while
o Drain the water from the transmission oil cooler and                 shifting. Therefore torque loads and directional changes
    replace it with a proper mixture of antifreeze coolant.            should be made at low engine speeds. If it is found that a
    NOTE: This operation will usually occur when the engine            failure was caused by a shock load, any warranty claim will
    raw water cooling system is properly winterized.                   be denied.

o   Clean up the transmission and touch-up unpainted areas
    (use heat resistant paint).                                         A CAUTION: System-related noises or vibrations can
o   Fill the transmission with Dextron III ATF fluid to pre-            occur at low engine speeds which can cause gear rattle
    vent internal corrosion.                                            resulting in damage to the engine and/or transmission.
o   Loosen attaching hardware from the transmission                     BORG WARNER is not responsible for total system-
    output flange and propeller shaft coupling flange before            related torsional vibration of this type.
    removing the boat from the water. Separate the flanges
    and spray with lubricant.                                          If any problems occur with the transmission, see
o   Inspect the gear shift cable, linkage, and attachments.            TRANSMISSION TROUBLESHOOTING in this manual.
    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 service.



OIL COOLERS
The continued flow of raw water through the cooler will, in            If water has contaminated the fluid, the transmission fluid
time, erode the inside of the cooler causing cross leaks to            needs to be cleaned out and replaced with fresh fluid. It will
occur. These internal cooler leaks will cause one of the               take several fluid changes to get rid of the contamination.
following two problems:                                                Check your dipstick each time until it appears as pure
1. Transmission fluid will leak into the flow of raw water             transmission fluid. Change the transmission filter and clean
     and be discharged overboard through the engine exhaust.           out the fluid lines that connect to the cooler.
    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 facility.
2. The raw water will leak into the transmission fluid                 A transmission cooler may last ten years or more but, in
     causing an increase in transmission fluid. This                   some circumstances, depending on operating hours, tropical
     contaminated fluid will appear as strawberry cream. The           waters, maintenance, etc. it might only last half that time.
     transmission will eventually fail.                                WESTERBEKE recommends having a spare cooler aboard.
Either case requires an immediate response:
1. Install a new oil cooler.
2. Refill the transmission with DEXTRON III ATF.




                                                              Engines & Generators

                                                                  41
                                       ZF MARINE TRANSMISSIONS
DESCRIPTION                                                          NOTE: When installing the transmission, make certain that
The infonnation below is specific to the ZF Transmissions,           shifting is not impeded by restricted movability of the
the TRANSMISSION TROUBLESHOOTING SECTION                             Bowden cable or rod linkage, by unsuitably positioned guide
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                      gear housing. Refer to the WESTERBEKE parts list.
transmission 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          The transmission is suitable for single lever remote control.
bearing is not required, since the propeller thrust will be          Upon loosening the retaining screw, the actuating lever can
taken by the transmission bearing, provided the value                be moved to any position required for the control elements
specified under SPECIFICATIONS is not exceeded.                      (cable or rod linkage). Make certain that the shift lever does
However, the output shaft should be protected from                   not contact the actuating lever cover plate: the minimum
additional loads. Special care should be taken to prevent            distance between lever and cover should be O.5mm.
torsional vibration. When using a universal joint shaft, make        The control cable or rod should be arranged at right angle to
certain to observe the manufacturers instructions.                   the actuating shift lever when in the neutral position. The
Even with the engine solidly mounted, the use of flexible            neutral position of the operating lever on the control console
coupling or "DRIVESAVER" will reduce stress in the                   should coincide with the neutral position of this lever.
gearbox bearings caused by hull distortions, especially in           The shifting travel, as measured at the pivot point of the
wooden boats or where the distance between transmission              actuating lever, between the neutral position and end
output flange and stem gland is less than about 800mm.               positions A and B should be at least 35mm for the outer and
                                                                     30mm for the inner pivot point.
                                                                     A greater amount of shift lever travel is in no way
                               ../"        ZF 15M                    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 1;>e indicated
                                                                     by slow clutch engagement or no engagement at all.
                                                                     NOTE Checkfor proper lever travel at least each season.
                                                                                                          NEUTRAL
                                                                                                             N




  A    CAUTION: The position of the mechanism behind                                             SHIFT - -
  the actuating lever is factory-adjusted to ensure equal                                        LEVER
  shift1ever travel from..-neutral position A and B. If
  this mechanism is in any way tampered with, the                                                                COVER
  transmission warranty will be void.




                                                         Engines & Generators
                                                                                                     O.Smm   F
                                                                                                     MINIMUM DISTANCE


                                                                42
                                                     ZF MARINE TRANSMISSIONS
INITIAL OPERATION                                                                         OPERATING TEMPERATURE
All HBW marine transmissions are test-run on a test stand                                 The maximum permissible ATF temperature should not exceed
with the engine at the factory prior to delivery. For safety                              230 (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
(DEXRON II or DEXTRON III). The fluid level should be                                      A CAUTION:-" thtrtransmissio" fluid temperature is
up to the index mark on the dipstick. To check the fluid level,                             too high, stop the engine immediately and check the
just insert the dipstick, do not screw it in. Screw the dipstick.                           transmission fluid.
into the case after the fluid level is checked and tighten. Do
not forget the sealing ring under the hexhead of the dipstick.
Check for leaks and change the fluid after the first 25 hours,                            LOCKING THE PROPELLER
also make a visual inspection of the coupling, oil cooler and                             Locking of the propeller shaft by an additional brake is not
hoses, and shift cables.                                                                  required: use the gear shift lever position opposite your direc-
                                                                                          tion of travel for this purpose. Never put the gear shift in the
                 "          DIPSTICK                                                      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
                                                              nl'\lllollYllolollON        being sailed, being towed, or anchored in a river, as well as
                                             FLUID           OPERATING                    operation of the engine with the propeller stopped (for charg-
                                                                                          ing the battery), will have no detrimental effects on the trans-
                                                                                          mission
                                                                                          DAILY OPERATION
                                                                                          o    Check the transmission fluid.
                                              FLUID LEVEL.                                o    Visually check the gear shift linkage and transmission.
             Intt,l
                 I
                                                                                          o    Start the engine in neutral, allowing a few minutes at
             ~          "
                                                                                               idle to warm the fluid.
 FLUI~   DRAIN .
                    I                                                                     o    Shift into gear.
FLUID CHANGE                                                                              NOTE: Too low an idle speed will produce a chattering noise
                                                                                          from the transmission gear and damper plate. In such cases
Change the fluid for the first time after about 25 hours of
                                                                                          the idle speed should be increased
operation, then every 250 operating hours or at least once a
year or when you change engine oiL                                                        For additional information refer to the following text in this
                                                                                          Transmission Section: SHAFT COUPLINGS, MAINTENANCE
Removing the fluid                                                                        AND TRANSMISSION TROUBLESHOOTING.
Push a suction pump hose down through the dipstick hole to
the bottom of the housing and suck out the fluid. (If space
allows, use the transmission drain). Remove the drain plug                                         ZF TRANSMISSIONS SPECIFICATIONS
from the bottom of the transmission and allow the fluid to
drain into a container, then reinstall the plug with its sealing                            General                     (ZF Standard Transmission) Case'
washer. Wipe down the transmission and properly dispose of                                                               hardened helical gears, with a
the used fluid. After running the engine, shut down and                                                                 servo-operated multiple disc clutch
recheck the fluid level.                                                                    Gear Ratio (optional)       ZF 15MA (1.88:1 or 2.63:1)
Drain plug torque            20 - 25 fUlbs                                                  Note: There are a variety   ZF 10MA (1.79:1)
                                                                                            of gear ratios available.   ZF 12MA (2.63:1)
                                                                                            Only a few are listed.      ZF 15MIV (2.13:1 or 2.72:1)
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 - " or III
this sealing washer.                                                                        Propeller Shaft             Right-hand rotation for above models
                                                                                            Direction of Rotation       listed.

  A WARNING: Never pull out the dipstick while the
  engine is running. Hot fluid will splash from the dip-
  stick hole. This could cause severe burns.




                                                                         Engines & Generators

                                                                                     43
                                           ZF MARINE TRANSMISSIONS
   OPERATING TEMPERATURE                                                     MAINTENANCE
                                                                             Transmission maintenance is minimal. Keep the exterior
                                                                             housing clean, check the fluid level as part of your regular
     A CAUTION: If the transmission fluid temperature is                     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 fluid.                                                     and corrosion. Make certain the air vent is clear and when
                                                                             checking the fluid level look for signs of water contamination
   Normal operating temperature of the transmission fluid                    (fluid will appear as strawberry cream).
   should be in the range of 1220 F (50" C) to 2120 F (1000 C).
   A maximum temperature of 2660 F (1300 C) may b~ only                      Lay-up/Wi.nterize
   reached for a short time.                                                 Storage requires special care. Follow these procedures:
   Make certain there is enough space around the transmission                o   Drain water from the transmission oil cooler and replace
   to provide good ventilation and cooling.                                      with a proper mixture of antifreeze coolant.
   TRANSMISSION COOLER                                                           NOTE: This operation will normally occur when the
   Coolers are standard equipment for the ZF lOM;ZF 12M,                         engine raw water cooling system is properly winterized
   ZF 15M, ZF 15MA, ZF 15MIY, and the ZF 25M.                                o   Clean up the transmission and touch up unpainted areas
   The cooler is a separate part of the transmission which                       (use heat resistant paint).
   prevents any possibilities of coolant diluting the transmission           o   Fill the transmission with Dextron III ATF fluid to
   fluid. However, the continued flow of coolant thru the cooler                 prevent internal corrosion (extended storage only, twelve
   will, in time, erode the inside of the cooler causing external                months or more).
   leaks.                                                                    o   Loosen attaching hardware from the transmission output
   A transmission cooler may last ten years or more but, in                      flange and propeller shaft coupling flange before
   some circumstances, depending on operating hours, tropical                    removing the boat from the water. Separate the flanges
   waters, maintenance, etc. it might only last half that time.                  and spray with lubricant.
   WESTERBEKE recommends having a spare cooler aboard.                       o   Inspect the gear shift cable, linkage, and attachments.
                                                                                 Look for corrosion of the end fittil').gs, cracks Qr cuts in
                                                                                 the conduit, and bending of the actuator rods. Lubricate
                                                                                 all moving parts.
                                                                                 NOTE: lfthe transmission is to be storedfor 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
TRANSMISSION



                                            PERIODICALLY INSPECT FOR
                                             EROSION AND LEAKAGE




                                                                                                                                   '-t---GEAR
                                                                                                                                          . SHIFT




                                                                                                       For additional information contact:
                                                                                                       ZF MARINE GEAR
                                                                                                       ZF Industries
                                                                                                       Marine US Headquarters
                                                                                                       3131 SW 42nd Street
                                                                                                       Fort Lauderdale, FL 33312
                                                                                                       Tel.: (954) 581-4040
                                                                                                       Fax: (954) 581-4077



                                                                 Engines & Generators

                                                                        44
                                     PRM NEWAGE TRANSMISSIONS
                                                MODELS 80 AND 120
                                                                  Push a suction pump hose down through the dipstick hole
                                                                  to the bottom of the housing and suck out the fluid. (If space
                                                                  allows, use the transmission drain). Remove the drain plug
 THE MODEL 720 HAS A BREATHER                                     from the bottom of the transmission (I" with sealing washer)
 FITTING ON THE TOP OF THE CASE                                   and allow the fluid to drain into a container, then reinstall the
                                                                  plug with its sealing washer. Wipe down the transmission and
                                                                  properly dispose of the used fluid. After running the engine,
                                                                  shut down and re-check the fluid level.
                                     --.rllD,"nrV 7/2" HEX PLUG
                                         MODEL 80 (MODEL 720 USES NOTE: When changing the fluid, take care not to lose the
                                         A 8MM HEX PLUG) .        drain plug sealing washer. The drain plug will leak without
                                                                  this sealing washer.

                                                                      A   WARNING: Never pullout the dipstick while the
                                                                      engine is running. Hot fluid will splash from the dipstick
                                                                      hole. This could cause severe burns.

                                                                     DAILY OPERATION
                                                                     o
                                                              Check the transmission fluid.
                                                      FULL           0
                                                              Visually check the gear shift linkage and transmission.
                                                                     o
                                                              Start the engine in neutral, allowing a few minutes at
                                                    LOW       idle to warm the fluid.
                                        "           ~    0 Shift into gear.
                                        .'    .     '~NOTE: Too low an idle speed will produce a chattering noise

                                                     ~ GEAR SHIFTING
                                                         from the transmission gear and damper plate. In such cases
                                      SEAUNG WASHER      the idle speed should be increased


                                                                     The engine must be at idle. Pause in neutral before
                                                                     selecting ahead or astern. Transmission models PRM 80 and
                                                                     120 are ideal for single lever engine controls, controlling
                                                                     both the throttle and the gear shift at one time.
INITIAL OPERATION
Remove the dipstick and fill the gear box with automatic              A    WARNING: When shifting gears, bring the engine
transmission fluid (ATF) Dextron m. Fill the transmission             throttle to idle and pause in neutral before shifting
with the recommended capacity of fluid.                               ahead or astern.
Model PRM80-1.0 U.S. pint (0.6L).
Model PRM 120-1.4 U.S. pints (0.8L).
NOTE Always clean the area around the dipstick plug before           LOCKING THE PROPELLER
filling with fluid. Replace the dipstick by screwing it down.        Locking of the propeller shaft by an additional brake is not
Run the engine to warm up the fluid and after shutting down          required: use the gear shift lever position opposite your
the engine, re-check the fluid level.                                direction of travel for this purpose. Never put the gear shift
                                                                     in the position corresponding to the direction of travel of the
CHANGING THE TRANSMISSION FLUID                                      boat.
Change the fluid for the first time after about 25 hours of          WHEN UNDER SAIL OR BEING TOWED
operation, then every 250 operating hours or at least once
a year or when you change engine oil. Check for leaks and            Rotation of the propeller without load, such as when the boat
make a visual inspection of the shift cables and shaft               is being sailed, being towed, or anchored in a river, as well as
coupling.                                                            operation of the engine with the propeller stopped (for
                                                                     charging the battery), will have no detrimental effects on the
                                                                     transmission




                                                         Engines & Generators

                                                                45
                                       PRM NEWAGE TRANSMISSIONS
                                                    MODELS 80 AND 120                                   N
                                                                                                    NEUTRAL
CONTROL CABLES                                                                                                        I

NOTE: When installing the transmission, make certain that                                                   35.......:
                                                                                               Ir 30'
                                                                                                                    .1

shifting is not impeded l:Jy restricted movability of the                                                   30'11
Bowden cable or rod linkage, l:Jy unsuitably positioned guide                              \ :I  ' ..J!
sheaves, too small a bending radius, etc.                                                   ;11\  tI;.!=i.#~t:I;::1==:=::I~
                                                                                          < !!)1'       0      /'          II
The control cable or rod should be arranged at right angle to               ACTUATING    ~, ~D'               .   i
                                                                            SHIFT LEVER ~. \                              SHIFT CABLE AND BRACKET
the actuating shift lever when in the neutral position. The
neutral position of the operating lever on the control console
should coincide with the neutral position of this lever.                . A greater amount of shift lever travel is in no way
The shifting travel, as measured at the pivot point of the                detrimental and is recommended. However, if the lever
actuating lever, between the neutral position and end                     travel is shorter, proper clutch engagement might be impeded
positions A and B should be at least 35mm for the outer and               which; in tum, would mean premature wear, excessive heat
30mm for the inner pivot point                                            generation and clutch plate failure. This would be indicated
                                                                          by slow clutch engagement or no engagement at all.
TROUBLESHOOTING                                                           NOTE Checkfor proper lever travel at least each season.
                Problem                         Probable Cause                                     Verification/Remedy
  Excessive noise at low speeds        1. Engine idle speed too low                  1. Increase idling speed
  Excessive noise at all speeds        1. Defective coupling                         1. InspecVreplace coupling if necessary
                                       2. Shaft misalignment                         2. Check alignment with feeler gauge
                                       3. Prop out of balance                        3. Remove, check pitch, balance and weight
    Fluid needs constant topping off   1. Power too high                             1. Compare engine and transmission data
                                       2. Ruid leak                                  2. Inspect seals, drain, check for fluid leaks
  Difficulty in moving lever control   1. Poor installation of cable                 1. InspecVreplace coupling if necessary
                                       2. Faulty cable                               2. Check alignment with feeler gauge
  Escape of pressure from gearbox      1. Defective breather                         1. Inspect breather (Model 120), contact a Distributor or your
  when dipstick is removed                (Model 120)                                   WESTERBEKE dealer


MAINTENANCE/SERVICE                                                      If a major problem should occur, contact your Westerbeke
Make certain the transmission fluid is changed annually.                 dealer or a NEWAGE distributor. To avoid prejudicing
If the fluid should become contaminated by water or the                  warranty rights, do not undertake repair work on the
gearbox suffers major mechanical damage, the gearbox                     gearbox without first contacting NEWAGE
must be thoroughly flushed out and re-filled with fresh fluid            TRANSMISSIONS liMITED or a NEWAGE distributor
to the correct specifications. .                                         or your WESTERBEKE dealer.
NEWAGE TRANSMISSIONS LTD. has distributors around
the world. Listed here are those in the United States.                   Warranty
                                                                         Newage transmission limited warrants that all PRM Newage
Atlantis Marine Gear Supply Inc.                                         Transmissions will be free from defects in material and
418 Boston Street                                                        worlananship under normal use and service for a period or
Topsfield, MA 01933                                                      twenty-four months.
Tel: 978-887-0001
Fax: 978-887-5599                                                        All PRM Transmissions must be correctly installed, aligned,
                                                                         and maintained.
Hamilton Jet
1111 NW Ballard Way
Seattle, WA 98107
Tel: 206-784-8400
Fax: 206-783-7323

Transmission .Marine
223 Southwes133 Court
P.O. Box 21086
Ft. Lauderdale, FL 33335-1086
Tel: 954-467-1540
Fax: 954-467-1525
Or contact your Westerbeke dealer.


                                                                Engines & Generators

                                                                       46
                                      TRANSMISSION TROUBLESHOOTING                                                      I



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

                 Problem                                 Probable Cause                                           Verification/Remedy
 Transmission gears cannot be shifted.         1. Actuating lever is loose.                        1. Tighten damping bolt on shifting 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. Shift lever is binding against cover plate.      3. Detach the shift cable and operate the lever by hand.
                                                                                                      Clearance should be 0.02 in (0.5mm).
 Transmission shifts into gear,                1. Output coupling is not tuming.                   1. Transmission needs professional attention.
 but 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 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 turning.                        A folding propeller may be jammed. A variable pitch
                                                                                                      propeller may be in "no pitch" position.
 Delay of gear engagement or engages           1. Lever travel Nto B not equal to N to A.          1. Adjust cover plate until the lever is exact mid-position.
 only after an increase in speed.                  Refer to diagram.                                   Refer to SHIFT LEVER TEXT AND DIAGRAM.
                                               2. Shift level travel in insufficient.              2. Check shift lever cable length. See SHIFT LEVER DIAGRAM.
                                               3. Shift 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                inspect the damper plate between the transmission and the
                                                   misalignment between engine and                    engine. Replace if necessary.
                                                   driveshaft.
                                               2. Beginning damage of bearings in                  2. Transmission needs professional attention.
                                                  transmission 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 transmission coupling with and the driveshaft.
                                                   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. 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.
                                                   Damaged sealing ring.~
                                               2. Misalignment of output flanges.                  2. Check alignment. Must be within 0.003 in (O.OBmm).

NOTE: If you suspect a major problem in your transmission,
immediately contact your WESTERBEKE dealer or an
authorized marine transmission facility.

                                                                          Engines & Generators

                                                                                    47
               PROPELLER RECOMMENDATION CHART
                   TRANSMISSION               PROPELLER                              PROPELLER
                   RATIO                      DIAMETER/PITCH                         BLADE (RH)

44A FOUR
(40 hp/3600 rpm)   2.0:1 .................. 170 x 10P. ........................ 2 Blade
                                                170 x BP. . ....................... 3 Blade
                   2.47:1 ................... 1BO x 11P. .................... 2 Blade
                                                1BO x 9P. ................. ... 3 Blade
                   2.72:1 .................... 1BO x 13P. ...................... 2 Blade
                                                1BO x 11P. ....................... 3 Blade
                    2.99:1 .................... 200 x 13P. ....................... 2 Blade
                                                200 x 11P. .................... 3 Blade


35C THREE
(29 hp/3600 rpm)   2.0:1 .................. 140x 10P. ................... 2 Blade
                                                140 x BP. ... ...................... 3 Blade
                   2.47:1 ..................160 x 11P. ..................... 2 Blade
                                                160 x 9P. ...........................3 Blade
                   2.63:1 .....................170 x 13P. ............... : ....... 2 Blade
                                                170 x 11P. .................... 3 Blade
                   2.99:1 .................... 1BO x 13P. .................... 2 Blade
                                                1BO x 11P. ..................... .3 Blade


44B FOUR
(39 hp/3000 rpm)   2.0:1 ................... 170 x 11P. ..................... 2 Blade
                                                170 x 9P. ........................ 3 Blade
                   2.47:1 .................. 200 x 13P. ........................ 2 Blade
                                                200 x 11P. ........................ 3 Blade
                   2.72:1 ................. 200 x 14P. .................. 2 Blade
                                                200 x 12P. .. .................. 3 Blade
                   2.99:1 .................. 220 x 15P. .................... 2 Blade
                                                220 x 13P. .. .................... 3 Blade


35C THREE
(31 hp/3000 rpm)   2.0:1 ...................... 160 x 10P. .................... 2 Blade
                                                160 x BP. ....................... 3 Blade
                   2.47:1 ....................1BO x 13P. ..................... 2 Blade
                                                1BO x 11P. .............. :.... 3 Blade
                   2.72:1 .................... 200 x 12P. ....................... 2 Blade
                                                200 x 10P. ........................ 3 Blade
                   2.99:1 .................. 220 x 13P. ..................... 2 Blade
                                                220 x 11P. ....................... 3 Blade
                    NOTE: For reductions not included, consult the WESTERBEKE
                    factory for recommendations.



                                      Engines & Generators

                                            48
                                       LAY-UP & RECOMMISSIONING

General                                                                 Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft,             Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the off-            or higher. A fuel conditioner such as STABIL gasoline
season or for long periods of inactivity. Others prefer to              stabilizer should be added. Change the element in your
accomplish lay-up preparation themselves.                               gasoline/water separator and clean the metal bowl.
The procedures which follow will allow you to perform your              Re-install and make certain there are no leaks. Clean
own lay-up and recommissioning, or will serve as a checklist            up any spilled fuel.
if others do the procedures.                                            Fuel System [Diese~
These procedures should provide protection for your                     Top off your fuel tanks with No.2 diesel fuel. Fuel additives
engine/generator during a lay-up and also help familiarize              such as BlOB OR and STABIL should be added at this time to
you with its maintenance needs.                                         control algae and condition the fuel. Care should be taken
If you have any questions regarding lay-up procedures, call             that the additives used are compatible with the primary fuel
your local servicing dealer. He will be more than willing to            filter/water seperator used in the system. Change the element
provide assistance.                                                     in your primary fuel filter/water seperator, if the fuel system
                                                                        has one, and clean the seperator sediment bowl.
Propeller Shaft Coupling [Propulsion Engine]
                                                                        Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
                                                                        fuel system, as needed. Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
                                                                        for 5 - 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water, and during
                                                                        system. Check for any leaks that may have been created in
storage in the cradle. The flexibility of the boat oftens puts a        the fuel system during this servicing, correcting them as
severe strain on the propeller shaft or coupling or both, while
                                                                        needed. Operating the engine for 5 - 10 minutes will help
the boat is taken out or put in the water. In some cases, the
                                                                        allow movement of the treated fuel through the injection
shaft has actually been bent by these strains. This does not
                                                                        equipment on the engine.
apply to small boats that are hauled out of the water when
not in use, unless they have been dry for a considerable                Raw Water Cooling Circuit
period of time.                                                         Close the through-hull fitting. Remove the raw water intake
Fresh Water Cooling Circuit                                             hose from the fitting. Place the end of this hose into a five
                                                                        gallon bucket of clean fresh water. Before starting the engine,
A 50-50 solution of antifreeze and distilled water is recom-
                                                                        check the zinc anode found in the primary heat exchanger on
mended for use in the fresh water cooling system at all times.
                                                                        the engine and clean or replace it as required and also clean
This solution may require a higher concentration of antifreeze,
                                                                        any zinc debis from inside the heat exchanger where the zinc
depending on the area's winter climate. Check the solution to
                                                                        anode is located. Clean the raw water strainer.
make sure the antifreeze protection is adequate.
                                                                        Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed, drain an appropriate amount
                                                                        fresh water through the system. When the bucket is empty,
from the engine block and add a more concentrated mixture.
                                                                        stop the engine and refill the bucket with an antifreeze
Operate the engine to ensure a complete circulation and mix-
                                                                        solution slightly stronger than needed for winter freeze
ture of the antifreeze concentration throughout the cooling
                                                                        protection in your area.
system. Then recheck the antifreeze solution's strength.
                                                                        Start the engine and allow all of this mixture to be drawn
Lubrication System                                                      through the raw water system. Once the bucket is empty, stop
With the engine warm, drain all the engine oil from the oil             the engine. This antifreeze mixture should protect the raw
sump. Remove and replace the oil filter and fill the sump               water circuit from freezing during the winter lay-up, as well
with new oil. Use the correct grade of oil. Refer to the                as providing corrosion protection.
ENGINE LUBRICATING OIL pages in this manual for                         Remove the impeller from your raw water pump (some
"engine oil change".                                                    antifreeze mixture will accompany it, so catch it in a bucket).
Run the engine and check for proper oil pressure and make               Examine the impeller. Get a replacement, if needed, and a
sure there are no leaks.                                                cover gasket. Do not replace the impeller (into the pump)
                                                                        until recommissioning, but replace the cover and gasket.

 A CAUTION: Do not leave th~ engine's old engine                        Intake Manifold and Thru-Hull Exhaust
                                                                        Place a clean cloth, lightly soaked in lubricating oil, in the
 oil in the sump over the lay-up 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 visable at
 chemicals which can reduce the life of your engine's                   recommissioning, 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 start-up. The thru-hull
                                                                        exhaust port can be blocked in the same manner.



                                                           Engines & Generators

                                                                   49
                                        LAY-UP & RECOMMISSIONING
Starter Motor                                                        Spare Parts
Lubrication and cleaning of the starter drive pinion is              Lay-up time provides a good opportunity to inspect your
advisable, if access to the starter permits its easy removal.        WES1ERBEKE engine to see if external items such as drive
Make sure the battery connections are shut off before                belts or coolant hoses need replacement Check your basic
attempting to remove the starter. Take care in properly              spares kit and order items not on hand, or replace those items
replacing any electrical connections removed from the starter.       used during the lay-up, such as filters and zinc anodes. Refer
                                                                     to SPARE PARTS section of this manual.
Cylinder Lubrication
If you anticipate a long lay-up period (12 months or more)           Recommissioning
WES1ERBEKE recommends removing the glow plugs or                     The recommissioning of your WES1ERBEKE engine after a
fuel injectors for access to the cylinders. Squirting light          seasonal lay-up generally follows the same procedures as
lubricating oil into the cylinders to prevent the piston rings       those presented in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls. Rotate the engine by hand       section regarding preparation for starting and normal starts.
two revolutions then replace the glow plugs or" injectors.           However, some of the lay-up procedures will need" to be
Make sure you have a replacement if removing the injector"           counteracted before starting the engine.
sealing washer for the ~njector and fuel "return line.
                                                                     1. Remove the oil-soaked cloths from the intake manifold
Intake Manifold [GasolineJ                                           2. Remove the raw water pump cover and gasket. and discard
Clean the filter screen in the flame arrester, and place a clean        the old gasket. Install the raw water pump impeller
cloth lightly soaked in lube oil around the flame arrester to           removed during lay-up (or a replacement, if required).
block any opening. Also place an oil-soaked clqth in the                Install the raw water pump cover with a new cover gasket.
through-hull exhaust port. Make a note to remove cloths prior
to start-up!.                                                        3. Reinstall the batteries that were removed during the lay-
                                                                        up, and reconnect the battery cables, making sure the
Intake Manifold and Thru-Hull Exhaust[Diesel]                           terminals are clean and that the connections are tight.
Place a clean cloth, lightly soaked in lubricating oil, in the          Check to make sure that the batteries are fully charged.
opening of the intake manifold to block the opening. Do not
shove the cloth out of sight. (If it is not visible at recommis-
sioning, and an attempt is made to start the engine, you may            A    CAUTION: Wear rubber gloves, a rubber apron,
need the assistance of a servicing dealer.) Make a note to              and eye protection when servicing batteries. Lead acid
remove the cloth prior to start-up. The through-hull exhaust            batteries emit hydrogen, a highly explosive gas, which
port can be blocked in the same manner.
                                                                        can be ignited by electrical arcing Dr a lighted
BAnERIES                                                                cigarette, cigar, Dr pipe. Do not smoke Dr allow an
If batteries are to be left on board during the lay-up period,          open flame near the battery being serviced. Shut off
make sure they are fully charged, and will remain that way,             all electrical equipment in the vicinity to prevent
to prevent them from freezing. If there exists any doubt that
                                                                        electrical arcing during servicing.
the batteries will not remain fully charged, or that they will
be subjected to severe environmental conditions, remove
the batteries and store them in a warmer, more compatible            4. Remove the spark plugs, wipe clean, re-gap, and install to
environment.                                                            proper tightness [gasoline].
                                                                     5. Check the condition of the zinc anode in the raw water
  A Warning: Lead acid batteries emit hydrogen, a                       circuit and clean or replace the anode as needed. Note that
  highly-explosive gas, which can be ignited by electrical              it is not necessary to flush the antifreeze/fresh water
  arcing Dr a lighted cigarette, cigar, Dr pipe. Do not                 solution from the raw water coolant system. When the
                                                                        engine is put into operation, the system will self-flush in a
  smoke Dr allow an open flame ngar the battery being
                                                                        short period of time with no adverse affects. It is
  serviced. Shut off all electrical equipment in the                    advisable, as either an end of season or recommissioning
  vicinity to prevent electrical arcing during servicing~               service, to inspect the area where the zinc is located in the
                                                                        heat exchanger and clear any and all zinc debris from that
                                                                        area.
Transmission [Propulsion EngineJ
                                                                     6. Start the engine in accordance with procedures described
Check or change the fluid in the transmission as required.
                                                                        in the PREPARATIONS FOR INmALSTART-UP section of
Wipe off grime and grease and touch up any unpainted areas.             this manual.
Protect the coupling and the output flange with an anti-corro-
sion coating. Check that the transmission vent is open. For
additional information, refer to the TRANSMISSION
SECTION.

                                                            Engines & Generators

                                                                   50
                                   44A & 448 FOUR ENGINE SPECIFICATIONS
                          SPECIFICATIONS                                                                        FUEL SYSTEM
Engine Type                 Diesel, four-cycle, four-cylinder, fresh water-         General                      Open flow, self priming.
                            cooled, vertical in-line overhead valve
                            mechanism ..                                            Fuel                         No.2 diesel oil (cetane rating of 45 or higher).
Displacement                107.3 cubic inches (1.758 liter)                        Fuel Injection Pump          In-line plunger type (BOSCH).
Aspiration                  Naturally aspirated.                                    Nozzle                       Throttle type.
Combustion Chamber          Swirl type.                                             Fuel Filter                  Spin-on replaceable.
Bore & Stroke               3.07 x 3.62 inches (78 x 92 mm)                        Air cleaner                   Replaceable paper filter cartridge.
Firing Order                1 - 3 - 4-2                                             AirAow                       140 cfm (3.9 cmm) at 3600 rpm.
                                                                                    (engine combustion)          93 cfm (26.2 cmm) at 3000 rpm.
Direction of Rotation       Clockwise, when viewed from the front.
                                                                                    Fuel Lift Pump               12 volt DC lift capacity of 5' (1.5 mm) solid state
Compression Ratio           22:1
Dimensions - inches (mm) Height: 18.6 inches (472.4 mm)                                                       COOLING SYSTEM
Engine Only              Width: 23.0 inches ( 584.2 mm)
                         Length:25.6 inches ( 914.4 mm)                             General                      Fresh water-cooled block, thermostatically-
                                                                                                                 controlled with heat exchanger.
Weight                      331 Ibs (150 kgs) without transmission.
                                                                                    Operating Temperature        170 -190 F(77 - 88 C)
Fuel Consumption            2.5 glhr (9.7Itrlhr) at 3600 rpm
                                                                                    Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
Inclination                 Continuous 15
                            Temporary 25 (not to exceed 30 min.)                   Raw Water Pump               Positive displacement, rubber impeller,
                                                                                                                 belt-driven.
                   TUNE-UP SPECIFICATIONS                                           Raw Water Flow               44AJFour          9.5 gpm at 3600 rpm
                                                                                    (measured before
Compression Pressure        427 psi (30 kg/cm') at 280 rpm                          discharge into exhaust       44B/Four          8.0 gpm at 3000 rpm
Minimum                     384 psi (27 kg/cm')                                     elbow) Approximate
Valve liming                Intake Opens                                            System Capacity             8.0 US qts (7.6 liters)
                            Intake Closes                                           (Fresh Water)
Spilled liming (Static)     17 (spill)
Valve Seat Angle            45
                                                                                                             LUBRICATION SYSTEM
                                                                                    General                      Pressure fed system.
Engine Speed                3600 rpm (44AlFour)
                            3000 rpm (44B/Four)                                     Oil Filter                   Full flow, paper element, spin-on type.
Valve Seat Angle            Intake 45                                              Sump Capacity                5.2 U.S. qts (5.4 liters)
                            Exhaust 30                                             (not including filter)
Valve Clearance             0.25 inches (0.0098 mm)                                 Operating Oil Pressure       50 - 60 psi (3.5 - 4.2 kg/cm')
(engine cold)                                                                       (engine hot)
Injector Pressure           1991 + 71 - 0 psi (140 + 5 - 0 kgf/cm').                Oil Grade                    API Specification CF or CG-4,
                                                                                                                 SAE 30, 10W-30, 15W-40
Engine liming               17 BTDC

                        ELECTRICAL SYSTEM
Starting Battery            12 Volt, (-) negative ground
Battery Capacity            400 - 600 Cold Cranking Amps (CCA)
DC Charging Alternator      51 Amp rated, belt-driven
Starting Aid                Glow plugs, sheathed type
Starter                     12 Volt, reduction gear




                                                                                                                                               Rev. July 2002


                                                                         Engines & Generators

                                                                              51
                                35C &350 THREE ENGINE SPECIFICATIONS
                           SPECIFICATIONS                                                                        FUEL SYSTEM
Engine Type                  Diesel, four-cycle, three-cylinder, fresh water-        General                      Open flow, self priming.
                             cooled, vertical in-line overhead valve
                             mechanism..                                             Fuel                         No.2 diesel oil (cetane rating of 45 or higher).

Displacement                 80.4 cubic inches (1.318 liter)                         Fuel Injection Pump          In-line plunger type (BOSCH).

Aspiration                   Naturally aspirated.                                    Nozzle                      Throttle type.

Combustion Chamber           Swirl type.                                             Fuel Riter                   Spin-on replaceable

Bore & Stroke                3.07 x 3.62 inches (78 x 92 mm)                         Air cleaner                  Replaceable paper filter cartridge.

Rring Order                                                                          AirFlow                      83.7 cfm (2.3 cmm) at 3600 rpm.
                             1- 3- 2
                                                                                     (engine combustion)          69.7 cfm (1.9 cmm) at 3000 rpm.
Direction of Rotation        Clockwise, when viewed from the front.
                                                                                     Fuel Lift Pump               12 volt DC lift capacity of 5' (1.5 mm) solid state
Compression Ratio            22:1
Dimensions - inches (mm) Height:           21.6 inches      (540.6 mm)                                         COOLING SYSTEM
Engine Only              Width:            20.1 inches      (510.5 mm)
                         Length:           22.4inches       (596 mm)                 General                      Fresh water-cooled block, thermostatically-
                                                                                                                  controlled with heat exchanger.
Weight                       276 Ibs (276 kgs) without transmission.
                                                                                     Operating Temperature        170 -190 F(n -88 C)
Inclination                  Continuous 15
                             Temporary 25 (not to exceed 30 min.)                   Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
                                                                                     Raw Water Pump               Positive displacement, rubber impeller,
                    TUNE-UP SPECIFICATIONS                                                                        belt-driven.

Compression Pressure         427 psi (30 kg/cm') at 280 rpm                          Raw Water Row                35C/Three         9.5 gpm at 3600 rpm
Minimum                      384 psi (27 kg/cm')                                     (measured before
                                                                                     discharge into exhaust       35D/Three         8.0 gpm at 3000 rpm
Valve liming                 Intake Opens                                            elbow) Approximate
                             Intake Closes
                                                                                     System Capacity              5.0 US qts (4.7 liters)
Spilled liming (Static)      17 (spill)                                             (Fresh Water)
Valve Seat Angle             45
                             17 BTDC
                                                                                                              LUBRICATION SYSTEM
Engine liming
                                                                                     General                      Pressure fed system.
Injector Pressure            1991 + 71 - 0 psi (140 + 5 - 0 kgf/cm').
                                                                                     Oil Riter                    Full flow, paper element, spin-on type.
Valve Seat Angle             Intake 45
                             Exhaust 30                                             Sump Capacity                3.9 U.S. qts (3.7 liters)
                                                                                     (not including filter)
Valve Clearance              0.0098 inches (0.25 mm)
(engine cold)                                                                        Operating Oil Pressure       50 - 60 psi (3.5 - 4.2 kg/cm')
                                                                                     (engine hot)
Engine Speed                 3600 rpm (35ClThree)
                             3000 rpm (35DlThree)                                    Oil Grade                    API Specification CF or CG-4,

                          ELECTRICAL SYSTEM
Starting Battery             12 Volt, (-) negative ground
Battery Capacity             400 - 600 Cold Cranking Amps (CCA)
DC Charging Altemator        51 Amp rated, belt-driven
Starting Aid                 Glow plugs, sheathed type
Starter                      12 Volt, reduction gear




                                                                                                                                                Rev. July 2002


                                                                           Engines & Generators

                                                                                52
                  44 FOUR AND 35 THREE TORQUE SPECIFICATIONS
                                          MAJOR BOLTS AND NUTS
                                                                                              TORQUE
                                                         Width        Clamp
         Bolt or Nut           Diameter     Pitch     across flats    length      kg -m           ft - Ib     N-m
Alternator Bracket                                                                3.8-5.3         27-38       36.6
Back Plate                                                                        3.3-4.8         24-35       32.5
Connecting Rod Cap               M9          1.0           14                     3.550.25       2772       34.82.5
Coolant Pump                                                                      1.62.4         12-17       17.2
Coolant Pump Pulley                                                               1.6  2.4       12-17       17.2
Coolant Temperature Sender                                                        1.21.8         9-13        12.2
Coolant Temperature Switch                                                        1.21.8         9-13        12.2
Crankshaft Pulley Nut            M18         1.5           27                     17.52.5        12718      17225
Cylinder Head Bolt               M10         1.25          14              87     90.5           65  4      88 5
Damper Plate                                                                      1.9 2.7        14-20       8.9
Delivery Valve Holder                                      19                     4.50.5         3254       44 5
Engine Mounts                                                                     3.24.7         23-34       31.1
Exhaust Manifold                                                                  1.62.4         12-17       7.2
Flywheel Bolt                    M12         1.25          19              29     13.50.5        984        1325
Fuel Filter Assembly                                                              4.66.8         33-49       44.7
Fuel Injection Nozzle Holder     M20         1.5           21                     5.50.5         4044       545
Fuel Injection Pipe Nut          M12         1.5                                  30.5           224        295
Fuel Leak-Off Pipe Nut           M12         1.5           18                     2.750.25       20 2       272.5
Fuel Solenoid Locknut                                                             4.00.5         28.936.2   39.18
Glow Plug                        M10         1.25          12              60     1.750.25       1272       17.22.5
Glow Plug Connection Plate       M4          0.7           8                      0.125  0.025   0.9  0.2   1.20.2
Intake Manifold                                                                   1.62.4         12-17       16.2
Main Bearing Cap Bolt            M10         1.25          17              81     5.25  0.25     382        51.52.5
Oil Filter                       M20         1.5                                  1.20.1         8.7 0.7    121
Oil Pan Bolt                     M8          1.25          12              25     2.80.3         20.32.2    275.3
Oil Pan Drain Plug               M14         1.5           22              10     4.0 0.5        294        395
Oil Pressure Sender                                                               1.21.8         9-13        12.2
Oil Pressure Switch              PT1/8                     26              11     1 0.2          7.21.4     102
Pressure Refief Valve            M22         1.5           22              33     5.00.5         364        495
Rear Plate Bolt (stamping)       M8          1.25          12              16     1.15 0.15      8.31.1     11.3 1.5
Rear Plate Bolt (standard)       M12         1.25          17              28     6.5 0.1        477        6410
Retaining Nut for Delivery       M16         0.75          19                     3.75  0.25     272        372.5
Valve Holder Body
Rocker Cover Bolt                M8          1.25          12              40     1.150.15       8.31.1     11.31.5
Rocker Shaft Bracket Bolt        M8          1.25          12              581    1.50.5         11 4       14.7  5
Sliding Sleeve Shaft             M10         1.25          14              29.5   3.60.6         264        356
Special Nut for                  M12         1.0           17                     20.5           144        205
Torque Spring Set
Starter B Terminal               M8          1.25          12                     1.1 0.1        807        10.81
Stop Solenoid                    M30         1.5           36                     4.50.5         3254       445
Thermostat Housing                                                                0.3-0.45        2-3         2.7
Thermoswitch                     M16         1.5           17              31.5   2.30.4         16.6  3    22.6  4



                                                    Engines & Generators

                                                         53
                                                         STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt.                     Metric bolt class numbers identify bolts by their strength with 10.9 the
Customary (inch) bolts are identifed' by markings two to grade eight             strongest.
(strongest), The marks correspond to two marks less than the actual grade,
Le,; a grade seven bolt will display five embossed marks.




NOTES: 1. Use the torque values listed below when specific torque values are not available.
            2. These torques are based on clean, dry threads. Reduce torque by 10% when engine oil istJsed.
            3. Reduce torques by 30% or more, when threading capscrews into aluminum.
    STANDARD BOLT & NUT TORQUE SPECIFICATIONS                                             METRIC BOLT &NUT TORQUE SPECIFICATIONS
                       SAE Grade 5        SAE Grade 67       SAE Grade 8
 Capsrew Body Size       Torque              Torque             Torque            Boll                   Grade 4.6      Grade 4.8    Grade 8.8  9.8 Grade 10.9
 (Inches)  (Thread)    ALb(Nm) .         FHb(Nm)             FHb(Nm)            Dia.    Wrench Size    A'Lb(Nm)       FHb(Nm)        FILb(Nm)     FILb (Nm)
      1/4 20               8 (11)            10 (14)             12 (16)
         28               10 (14)                                14 (19)            M3     5.5mm         0.3 (0.5)      0.5 (0.7)       1 (1.3)       1.5 (2)
                                                                                     M4      7mm          0.8 (1.1)       1 (1.5)         2 (3)        3 (4.5)
     5/16-18               17 (23)            19 (26)             24 (33)            M5      8mm          1.5 (2.5         2 (3)         4.5 (6)       6.5 (9)
         - 24              19 (26)                                27 (37)
      318-16               31 (42)            34 (46)             44 (60)         M8        10mm            3 (4)        4 (5.5)         7.5 (10)      11 (15)
         - 24              35 (47)                                49 (66)         M9        13mm           7 (9.5)       10 (13)         18 (25)       35 (26)
     7/16-14               49 (66)            55 (75)             70 (95)         Ml0       16mm           14 (19)       18 (25)         37 (50)       55 (75)
         - 20              55 (75)                                78 (106)
       1/2 -13             75 (102)           85 (115)           105 (142)        M12       18mm           26 (35)        33 (45)        63 (85)       97 (130)
           - 20            85 (115)                              120 (163)        M14       21 mm          37 (50)        55 (75)       103 (140)     151 (205)
                                                                                  M16       24mm           59 (80)       85 (115)       159 (215)     232 (315)
     9/16 -12             110 (149)          120 (163)           155 (210)
          -18             120 (163)                              170 (231)
                                                                                  M18       27mm           81 (110)     118 (160)       225 (305)     321 (435)
      5/8-11              150 (203)          167 (226)           210 (285)        M20       30mm          118 (160)     166 (225)       321 (435)     457 (620)
         -18              170 (231)                              240 (325)        M22       33mm          159 (215)     225 (305)       435 (590)     620 (840)
      314 -10             270 (366)          280 (380)           375 (508)
          -16             295 (400)                              420 (569)        M24       36mm          203 (275)     288 (390)       553 (750)    789 (1070)
                                                                                  M27       41 mm         295 (400)     417 (565)      811 (1100)    1154 (1565)
      7/8 - 9             395 (536)          440 (597)           605 (820)        M30       46mm          402 (545)     568 (770)      1103 (1495)   1571 (2130)
          -14             435 (590)                              675 (915)
        1- 8              590 (800)          660 (895)           910 (1234)       M33       51 mm         546 (740)     774 (1050)     1500 (2035)   2139 (2900)
         -14              660 (895)                              990 (1342)       M36       55mm          700 (950)     992 (1345)     1925 (2610)   2744 (3720)
NOTE: Formula to convert Ft-Lbs to Nm (Newton Meters) multiply Ft-Lbs by 1.356.

                                                  SEALANTS & LUBRICANTS
GASKETSISEALANTS
Oil based PERMATEX #2 and it's HIGH TACK equivalent are excellent all            Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolant
purpose sealers. They are effective in just about any joint in contact with      passages. Do not use tape sealants!
coolant, raw water, oil or fuel.
A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets            BOLTS & FASTENERS/ASSEMBLIES
and O-rings.                                                                     Lightly oil head bolts and other fasteners as you assemble them. Bolts and
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil    plugs that penetrate the water jacket should be sealed with PERMATEX #2 or
filter assembly.                                                                 HIGH TACK.
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer.     When assembling the flywheel, coat the bolt threads with LOCTITE blue.
When installing gaskets that seal around water (coolant) passages, coat both     Anti-seize compounds and thread locking adhesives such as LOCTITE protect
sides with WHITE SILICONE grease.                                                threaded components yet allows them to came apart when necessary.
                                                                                 LOCTITE offers levels of locking according to the job.
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position dur-
ing assembly.                                                                    LITHIUM based grease is waterproof, ideal for water pump bearings and stuff-
                                                                                 ing boxes.
Specialized gasket sealers such as HYLOMAR work well in applications requir-
ing non-hardening properties. HYLOMAR is particlarly effective on                Heavily oil all sliding and reciprocating components when assembling. Always
copper cylinder-head gaskets as it resists fuel, oil and water.                  use clean engine oil!


                                                                      Engines. & Generators

                                                                                54
STANDARD AND METRIC CONVERSION DATA

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

VOLUME
  Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =i n3
  Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt
  Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt
   Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
  Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
  Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
  Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
  US Pints (US pt) x .473 = Liters(L) x 2.113 = Pints
  US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
  US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons

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

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

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

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

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

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

TEMPERATURE
  Degree Fahrenheit (OF) = (OC X 1.8) + 32
  Degree Celsius (0C) = (OF - 32) x .56




                              Engines & Generators

                                    55
                                              SUGGESTED SPARE PARTS
                            WESTERBEKE MARINE DIESEL ENGINES
        CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION




                                                                                                        HARDWARE KIT
     RAW WATER PUMP      "","-.",,'~!"'"

     IMPELLER/GASKET




                                                                                                 AIR INTAKE FILTER
                                                                   ~~
                                                                      WATER SEPERATOR FILTER



  FUEL LIFT
  PUMP

                                           WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
                                           ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE (5 OTS.)
                                           AND A GALLON OF PREMIXED COOLANT.

                                                     SPARE PARTS KITS
WESTERBEKE also offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox.                                                       B Kit
Kit "A" includes the basic spares.                                                              Impeller Kit
Kit "B" is for more extensive off-shore cruising.                                               Water Pump Repair Kit
       AKit                                                                                     Thermostat Kit
       Impeller Kit                                                                             Zinc Anodes
       Heat Exchanger Gasket                                                                    Complete Gasket Kit
       Fuel Filter with Gasket                                                                  Heat Exchanger Gasket
       Oil Filter                                                                               Injector
       Drive Belt                                                                               Fuel Filter with Gasket
       Zinc Anodes                                                                              Oil Filter
                                                                                                Drive Belt
                                                 I "'fIV'/WESTERBEKE
                                                       I EnaitJes & Generators
                                                                56'
       EUROPEAN MARITIME COUNCIL REGISTRATION
                                 EUROPEAN ECONOMIC COUNCIL
                                                    Declaration of Conformity
Application of Council Directives                                             EMC 89/336IEEC 9
Standard(s) to Which Conformity is declared                                   EN50081-1
                                                                              EN50082-2
                                                                              EN55020
Manufacturer's Name and Address                                               Westerbeke Corporation
                                                                              150 John Hancock Road
                                                                              Myles Standish Industrial Park
                                                                              Taunton, MA 02780, USA
Type of Equipment                                                             Marine Diesel Engine
Product Name                                                                  Westerbeke Marine Diesel Engine
ModeI(s)                                                                      44A-Four I 35C-Three
Product Options                                                               All
Supplementary Information
1.) The equipment listed is only for use in Marine Applications aboard boats.
2.) The equipment listed must be located below decks on the vessel and permanently installed in it's location.
3.) The equipment listed must be wired to the grounding system of the vessel.
I the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and
Standard(s).                                                 /? ~                    / \/-
Place Taunton Massachusetts. U.S.A                           ~ _           ~
                                                                           (Signature)

Date April 3. 2000                                                               Carleton F. Bryant. Chief Operating Officer




 INTERNATIONAL MARINE CERTIFICATION INSTITUTE
       Rond Point Schuman 6, Box 6' B  1040 BRUXELLES  BELGIQUE' tel: +32 (0) 2-238-7892  fax: +32 (0) 2-238-noo

                                           CERTiFiCATE
                  We hereby certify that the engines(s) stated below meet the EC Directive 94/25/EC.
                                           1999I.M.C.1. Power Rating Report
I MANUFACTURER                       I                                 Westerbeke Corporation                                      I
I ADDRESS                            I        150 John Hancock Road Myles Standish Industrial Park Taunton MA 02780 USA            I
 MODEL NAME                                                                   44A-Four                                             I
 SPECIFICATIONS
 Engine Type                                                                        Inboard
 Fuel Tvpe                                                                           Diesel
 Aspiration Type                                                                    Natural

 Rating Level                             Highest Output 1            2          3            4          Lowest Output 5
 Crankshaft Power
 Propeller shaft Power
                            (kW)
                            (kW)
                                                 27
                                                 27
                                                                      
                                                                                
                                                                                             
                                                                                              
                                                                                                                 
                                                                                                                 
 at RPM                     (min")             3.600
                                                                                                              
 CertHication Number                                                          WESTEBIDOOh
 Signed                                                                   ,~      -"7_ J.r?~              .;-
                                                                       t-/
 Name                                                                        Lars E. Granholm
 Title                                                                       Manaaina Director
 EU NotHied Body No                                                                0609
 Date                                                                          3-April-2000

                                                  Manufacturer's verHication statement
      Power rating is in accordance with IMCI Proceedure. Compliance verHied in accordance with ISO 8665 and ISO 15584 (only for
                     inboard petrol en ines). This application form has not been lodaed with any other not Hied body.
 Company:                                                                      Westerbeke Corporation
 Date:.                                                                             3-April-2000
 Name:                                                                              Carl F. Brvant
 Title:                                                                     /I Chief Operating Officer
 Signature:                                                          I/,           /7.
                                                                                                ~
                                                                              v    C/ ..-'




                                                     Engines & Generators

                                                              57
            EUROPEAN MARITIME COUNCIL REGISTRATION
                                       EUROPEAN ECONOMIC COUNCIL

                                                                                                                                  ~

I
     INTERNATIONAL MARINE CERTIFICATION INSTITUTE
            Rond Point Schuman 6, Box 6 - B - t040 BRUXELLES - BELGIQUE -tel: +32 {OJ 2-238-7892 - fax: +32 (OJ 2-238-7700

                                                  CERTKFKCATE
                       We hereby certify that the engines(s) stated below meet the EC Directive 94/25/EC.
                                                19991.M.C.1. Power Rating Report
    I MANUFACTURER                         I                                  Westerbeke Corporation                                            I
    I ADDRESS                              I         150 John Hancock Road Myles Standish Industrial Park Taunton MA 02780 USA
    I MODEL NAME                           I                                        3SC-Three

     SPECIFICATIONS
     EnaineType                                                                                  Inboard
     Fuel Type                                                                                    Diesel
     Aspiration Type                                                                             Natural

     Ratina Level                                Hiahest Output 1            jgL               (3)         J4)       Lowest Output{S)
     Crankshaft Power
     Propeller shaft Power
                                 jkW)
                                  (kW)
                                                         21
                                                         20
                                                                               
                                                                                               
                                                                                                           
                                                                                                                            
                                                                                                                             
     at RPM                       (min")               3.600
                                                                                                                          
     CertHication Number                                                                   WESTERIDO..Q.4
     Signed                                                                      I   '-r.,/U     ." 7-     ~,

     Name                                                                                Lars E. Granholm
     litle                                                                               Managing Director
     EU NotHied Body No                                                                        0609
     Date                                                                                   3-April-2000

                                                                       ; verHication statement
          Power rating is in           , with IMCI                            I verHied in            I wijh ISO 8665 and ISO 15584 (only for
                         inboard petrol en lines). This application form has not been lodged with any other notHied body.
     Company:
     Date:
     Name:                                                                                 Carl F. Bryant
     litle:                                                                       /7  Chief Operatina Officer
     Signature:                                                               /./ '-;1YYA.               or
~                                                                               .!::.          .'-.




                                                                  Engines & Generators

                                                                             58
Engines & Generators


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