Westerbeke Diesel 63c Four Technical Manual

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Engines Generators 1050WMOW22001 1 0 5 0 SUGGESTED SPARE PARTS WESTERBEKE MARINE DIESEL ENGINES CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION THERMOSTAT GASKET HARDWARE KIT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive offshore cruising A Kit Impeller Kit Heat Exchanger Gasket Fuel Filter Oil Filter Drive Belt Zinc Anodes Fuel Lift Pump Filter MODEL HOSE KIT HOSE KITDUFFEL BAG Molded engine replacement hoses pack in a fII6IIIJ rugged canvas carrying bag B Kit Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Injector Fuel Filter Oil Filter Drive Belt WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL YOUR BRANDFOR AN OIL CHANGE AND A GALLON OF PREMIXED COOLANT Engines Generators 49 AND METRIC CONVERSION DATA LENGTHDISTANCE Inches inx 254 Millimeters mmx 0394 Inches Feet ftx 305 Meters mx 3281 Feet Miles x 1609 Kilometers kmx 0621 Miles VOLUME Cubic Inches in3x 16387 Cubic Centimeters x 061 in3 Imperial Pints IMP ptx 568 Liters Lx 176 IMP pt Imperial Quarts IMP qtx 1137 Liters Lx88 IMP qt Imperial Gallons IMP galx 4546 Liters Lx 22 IMP gal Imperial Quarts IMP qtx 1201 US Quarts US qtx 833 IMP qt Imperial Gallons IMP galx 1201 US Gallons US galx 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US ptx 473 LitersLx 2113 Pints US Quarts US qtx 946 Liters Lx 1057 Quarts US Gallons US galx 3785 Liters Lx 264 Gallons MASSWEIGHT Ounces ozx 2835 Grams gx 035 Ounces Pounds Ibx 454 Kilograms kgx 2205 Pounds PRESSURE Pounds Per Sq In psix 6895 Kilopascals kPax 145 psi Inches of Mercury Hgx 4912 psi x 2036 Hg Inches of Mercury Hgx 3377 Kilopascals kPax 2961 Hg Inches of Water H20x 07355 Inches of Mercury x 13783 H20 Inches of Water H20x 03613 psi x 27684 H20 Inches of Water H20x 248 Kilopascals kPax 4026 H20 TORQUE PoundsForce Inches inIbx 113 Newton Meters Nmx 885 inIb PoundsForce Feet ftIbx 1356 Newton Meters Nmx 738 ftIb VELOCITY Miles Per Hour MPHx 1609 Kilometers Per Hour KPHx 621 MPH POWER Horsepower Hpx 745 Kilowatts Kwx 134 MPH FUEL CONSUMPTION Miles Per Hour IMP MPGx 354 Kilometers Per Liter KmLKilometers Per Liter KmLx 2352 IMP MPG Miles Pe Gallons US MPGx 425 Kilometers Per Liter KmLKilometers Per Liter KmLx 2352 US MPG TEMPERATURE Degree Fahrenheit OF OC X 18 32 Degree Celsius 0C OF 32x 56 Engines Generators 48 mm mm Meters Meters kg kg oilsoaked cloth Engine The transmission and propeller half couplings should always be opened up and the bolts removed when the boat is hauled out of the water or moved from land to water and during storage in the cradle The flexibility of the boat often puts a severe strain on the propeller shaft or coupling or both while the boat is taken out or put in the water In some cases the shaft has actually been bent by these strains This does not apply to small boats that are hauled out of the water when not in use unless they have been dry for a considerable period of time Fresh Water Cooling Circuit A 5050 solution of antifreeze and distilled water is recommended for use in the coolant system at all times This solution may require a higher concentration of antifreeze depending on the areas winter climate Check the solution to make sure the antifreeze protection is adequate Should more antifreeze be needed drain an appropriate amount from the engine block and add ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust255ments be peiformed by a competent engine mechanic The information below is provided to assist the mechanic LOW COMPRESSION When low compression is found determine the cause by applying a small amount of oil in the cylinder thru the glow plug hole Allow the oil to settle Install the pressure gauge and repeat the above test If the compression reading rises dramatically the fault is with the rings If the compression valve does not rise the problem is with the valves A slight rise in compression would indicate a problem with both rings and the valves NOTE In case of severe vibrations and detonation noise have the injectors checked and overhauled by an authorized fuel injection service center Poor fuel quality contaminates and loss of positive fuel pressure to the injection pump will result in injector faults When reinstalling the glow plugs use antiseize compound SETTING THE IDLE SPEED PROPULSION ENGINE1 Warm the engine to normal operating temperature 2 Stick a piece of suitable reflecting tape on the crankshaft pulley 3 Idle the engine 4 Use the light of a photoelectric strobe type tachometer on the reflecting tape and check the value shown by the tachometer NORMAL IDLE SPEED 580 630 rpm NOTE The idle speed may vary according to the transmission and propeller 5 To adjust the engine idle speed loosen the lock nut of the idle adjustment bolt and tum the bolt clockwise to increase idle speed and to reduce NOTE Should engine rpm be in question verify as shown at the instrument panel See TACHOMETER KEEP LINKAGE WELL LUBRICATED THROTTLE STOP SCREW INJECTION PUMP For disassembly inspection reassembly and internal adjust255ments of the injection pump it is recommended the pump be taken to a qualified injection service shop authorized to service Diesel KiKi or Zexel injection equipment ENGINE STOP SOLENOID This solenoid is installed on the top rear of the injection pump and is activated by 12 VDC electrical current 1 The solenoid does not operate when the keyswitch is turned ON a Are the engine batteries turned ON b Is the 20 amp circuit breaker set c Is 12 VDC present at the solenoid connection 2 The solenoid does not stop the engine when the keyswitch is switched OFF a Check to see if 12 VDC is still present at the solenoid electrical lead with the key off bRemove solenoid from injection pump and ensure plunger and spring in the solenoid are not sticking INJECTION PUMP Engines Generators 44 AdobeUCS2 3 oil pressure oil pressure threaded ends ENGINE ADJUSTMENTS DRIVE BELT ADJUSTMENT Proper inspection service and maintenance of the drive belts is important for the efficient operation of your engine see Drive Belts under MAINTENANCE SCHEDULEDrive belts must be properly tensioned Loose drive belts will not provide proper alternator charging and will eventually damage the alternator Drive belts that are too tight will pull the alternator out of alignment andor cause the alternator to wear out prematurely Excessive drive belt tension can also cause rapid wear of the belt and reduce the service life of the coolant pumps bearing A slack belt or the presence of oil on the belt can cause belt slipping resulting in high operating temperatures and tachometer variations The drive belt is properly adjusted if the belt can be deflected no less than 38 inch lOmmand no more than 112 inch 12mmas the belt is depressed with the thumb at the mid255point between the two pulleys on the longest span of the belt A spare belt or belts should always be carried on board A WARNING Never attempt to check or adjust the drive belts tension while the engine is in operation Adjusting Belt Tension 1 Loosen the alternator adjusting strap bolt and the base mounting bolt 2 With the belt loose inspect for wear cracks and frayed edges 3 Pivot the alternator on the base mounting bolt to the left or right as required to loosen or tighten 4 Tighten the base mounting bolt and the adjusting strap bolt 5 Run the engine for about 5 minutes then shut down and recheck the belt tensions FUEL INJECTORS In case of severe vibrations and detonation noise have the injectors checked and overhauled by an authorized fuel injection service center Poor fuel quality contaminants and loss of positive fuel pressure to the injection pump can result in injector faults Since fuel injectors must be serviced in a clean room enviroment it is best to carry at least one extra injector as a spare should a problem occur Before removing the old injector clean the area around the base of the injector to help prevent any rust or debris from falling down into the injector hole If the injector will not lift out easily and is held in by carbon buildup or the like work the injector sidetoside with the aid of the socket wrench to free it and then lift it out The injector seats in the cylinder head on a copper sealing washer This washer should be removed with the injector and replaced with a new washer when the new injector is installed INJECTOR TO CYLINDER HEAD TIGHTENING TORQUE 40 261 4 HIb 55 261 05 kgfmEngines Generators 41 WESTERBEKE dealer excessively tight transmission service hours thereafter AdobeUCSBORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION FROM COOLER CONNECTION SHIPMENT For safety reasons the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft Before leaving the WESTERBEKE plant each transmission undergoes a test run with Dextron III ATF transmission fluid The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year if properly stored TRANSMISSION FLUID Check the transmission fluid level on the dipstick If the transmission has not been filled fill with Dextron III and continue to use this fluid During the first 25 hours of operation keep a lookout for any leakage at the bell housing output shaft and transmission cooler This fluid should be changed after the first 25 hours and approximately every 300 operating hours thereafter andor at winter layup A CAUTION Be certain the transmission is filled and the correct size cooler is properly installed before starting the engine SHIFT LEVER POSITION The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward FNeutral Nand Reverse Rshifting positions A detent ball located behind the transmission lever must work freely to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments An improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi255tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine speed Start the engine and set the throttle at idle speed allow the transmission fluid to warm up for a few minutes Neutral Move the gear shift lever to the middle position You should feel the detent This centers the actuating lever on the With the control in this position hydraulic power is completely interrupted and the output shaft of the does not turn NOTE Some transmissions are equipped with a neutral safety switch Unless the transmission actuating lever is perfectly aligned in neutral the engine starter will not activate Forward Move the gear shift lever to the forward position You should feel the detent The actuating lever267 on the transmission is in the forward position The output shaft and the propeller shaft move the boat in a forward direction Reverse Move the gear shift lever to the reverse position You should feel the detent The actuating lever on the transmission is in the reverse position The output shaft and the propeller should move the boat in a reverse direction asternNOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever Engines Generators 36 hours tropical HURTH TRANSMISSIONS DESCRIPTION The infonnation below is specific to the HBW Transmissions the TRANSMISSION SECTION applies to all models CONNECTION OF GEAR BOX WITH PROPELLER HBW recommend a flexible connection between the gearbox and the propeller shaft if the engine is flexibly mounted in order to compensate for angular deflections The installation of a special propeller thrust bear255ing is not required since the propeller thrust will be taken by the transmission bearing provided the value specified under SPECIFICATIONS is not exceeded However the output shaft should be protected from additional loads Special care should be taken to prevent torsional vibration When using a universal joint shaft make certain to observe the manufacturers instructions Even with the engine solidly mounted the use of a flexible coupling or DRIVESAVER will reduce stress in the gear255bo bearings caused by hull distortions especially in wooden boats or where the distance between transmission output flange and stem gland is less than about 32 in 812 mmHURTH HBW HURTH HBW COOLERA CAUTION The position of the mechanism behind the actuating lever is to ensure equal shift lever travel from neutral position A and B If this mechanism is in any way tampered with the transmission warranty will be void DRIVESAVER is a product of Globe Marine Rockland MA NOTE When installing the transmission make certain that shifting is not impeded by restricted movability of the Bowden cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius etc In order to mount a support for shift control cable connections use the two threaded holes located above the shift cover on top of the gear housing Refer to the WESTERBEKE parts list CONTROL CABLES The transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating lever can be moved to any position required for the shift control elements cable or rod linkageMake certain that the actuating lever does not contact the actuating lever cover plate the minimum distance between lever and cover should be OSmm The control cable should be arranged at a right angle to the actuating lever when in the neutral position The neutral posi255tion of the shift operating lever on the control console should coincide with the neutral position of the actuating lever The shifting travel as measured at the pivot point of the actuating lever between the neutral position and end pOitions A and B should be at least 35mm for the outer pivot pomt and 30mm for the inner pivot point A greater amount of shift lever travel is in no way detrimental and is recommended However if the lever travel is shorter proper clutch engagement might be impeded which in tum would mean premature wear excessive heat generation and clutch plate failure This would be indicated by slow clutch engagement or no engagement at all NOTE Check for proper actuating lever travel at least each season LEVER TRAVEL FORWARO B CHECK FOR EQUAL TRAVEL FROM NEUTRAL THRU FORWARD AND REVERSE SHIFT CO CABLE NEUTRAL N COVER ACTUATING LEVER Engines Generators 002 in 05mmMINIMUM CLEARANCE 34 1 1 wire attached engines electrical 6 8 wire load such USE FINE STRAND the positive ONE TWO AdobeUCSsn HOTE I I I I I J I lAlilU ROTE An onoff switch should be installed in this circuit to disconnect the starter from the battety in an emergency and when leaving the boat Twelve volt engine starters typically draw 200 to 300 amps when cranking A switch with a continuous rating of 175 amps at 12 VDC will nonnally serve this function but a switch must never be used to maken the starter circuit rI 630 FOUR ENGINE WIRING DIAGRAM 39144 t 225 ALARM e lutUIt I tl Itn ALT 225 T Engines Generators 27 ADMIRAL PANEL CAPTAIN PANEL 225 I AdobeUCSDC ELECTRICAL SYSTEM 7 Now check the voltage between the alternator output ter255minal Band ground If the circuit is good the voltage at the alternator will be the same as the battery or if an isola255tor is in the circuit the alternator voltage will be zero If neither of the above is true a problem exists in the circuit between the alternator and the battery Check all the connections look for an opening in the charging circuit TESTING THE STARTING ENGINE RUNNINGMULTI METER Cl25J 0 OM ENGINE c GROUND 8 Start the engine again Check the voltage between the alternator output and ground The voltage reading for a properly operating alternator should be between 135 and 145 volts If your alternator is overor undercharging have it repaired at a reliable service facility NOTE Before removing the alternator for repair use a voltmeter to ensure that 12 volts DC excitation is present at the EXC terminal if the previous test showed only bat255tery voltage at the B output terminal If 12 volts is not present at the EXC terminal trace the wiring and look for breaks and poor connections 12 VOLT DC CONTROL CIRCUIT The engine has a 12 volt DC electrical control circuit that is shown on the wiring diagrams that follow Refer to these diagrams when or when servicing the DC electrical system A CAUTION To avoid damage to the battery charging circuit never shut off the engIne battery switch while the engine is running Shut off the engine battery switch however to avoid electrical shorts when working on the engines electrical circuit BAnERY The minimum recommended capacity of the battery used in the engines 12 volt DC control circuit is 600 900 Cold Cranking Amps CCA Checking the Service Battery Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself GROUND SERVICE BATTERY TESTING THE SERVICE BATTERY ENGINE RUNNINGA CAUTION To avoid damaging the altemator diodes do not use a high voltage tester ie a meggerwhen performing tests on the altemator charging circuit Battery Care Review the manufacturers and then establish a systematic maintenance schedule for your engines starting batteries and house batteries D Monitor your voltmeter for proper charging during engine operation D Check the electrolyte level and specific gravity with a hydrometer D Use only distilled water to bring electrolytes to a proper level D Make certain that battery cable connections are clean and tight to the battery posts and to your engineD Keep your batteries clean and free of corrosion A WARNING Sulfuric acid in lead batteries can cause severe bums on skin and damage clothing Wear protective gear Engines Generators 26 along with AdobeUCSm a AdobeUCScloth and REMOTE OIL FILTER lbis popular accessory is used to relocate the engines oil fil255ter from the engine to a more convenient location such as an engine room bulkhead NOTE Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil Filter NOTE Refer to ENGINE OIL CHANGE in this manual for instructions on removing the oil filter To install simply remove the engine oil filter and thread on WESTERBEKEs remote oil filter kit as shown Always install this kit with the oil filter facing down as illustrated Contact your WESTERBEKE dealer for more information APPLY A THIN COAT OF CLEAN OIL TO THE ORING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING CONTACTS THE THE OUT CONNECTION HOSE MUST ATTACH TO THE IN CONNECTION AT THE REMOTE OIL FILTER THE IN CONNECTION HOSE MUST ATTACH TO THE OUT CONNECTION ATTHE OIL FILTER A CAUTION It is vital to install the oil lines cor255rectly If the oil flows in the reverse direction the by255pass valve in the filter assembly will prevent the oil from reaching the engine causing an intemal engine failure If there is no oil pressure reading shutdown immediately and check the APPLY A THIN COAT OF CLEAN OIL TO THE FILTER GASKET WHEN INSTALLING AFTER THE FILTER CONTACTS THE BASE TIGHTEN IT AN ADDITIONAL Engines Generators 22 AdobeUCSENGINE OIL ENGINE OIL CHANGE 1 Draining the Oil Sump Discharge the used oil through the sump drain hose attached to the front of the enginewhile the engine is warm Drain the used oil completely replace the hose in its bracket and replace the end cap securely NOTE Thread size for the lube oil drain hose capped end is 114 NPT Always observe the used oil as it is removed A yellowgray emulsion indicates the presence of water in the oil Although this condition is rare it does require prompt attention to prevent serious damage Call a quali255fied mechanic should water be present in the oil Raw water present in the oil can be the result of a fault in the exhaust system attached to the engine andor a siphoning of raw water through the raw water cooling circuit into the exhaust filling the engine This problem is often caused by the absence of an antisiphon valve its poor location or lack of maintenance 2 Replacing the Oil Filter When removing the used oil fil255ter you may find it helpful and cleaner to punch a hole in the upper and lower portion of the old filter to drain the oil from it into a container before removing it This helps to lessen spillage A small automotive filter wrench should be helpful in removing the old oil filter NOTE Do not punch this hole without first loosening the filter to make certain it can be removed Place some paper towels and a plastic bag around the fil255ter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engines cooling ability Keep your engine cleanInspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes off with the old oil filter If this rub255ber sealing gasket remains sealed against the filter bracket gently remove it When installing the new oil filter element wipe the filter gaskets sealing surface on the bracket free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter Screw the filter onto the threaded oil filter nipple on the oil filter bracket and then tighten the filter firmly by hand NOTE The engine oil is cooled by engine coolant flowing through passages in the oil filter bracket housing assembly OIL FILTER PN35828 PRESSURE SWITCH OIL FILTER ASSEMBLY NOTE Generic filters are not recommended as the mater255ial standords or diameters of important items on generic parts might be entirely different from genuine parts Immediately after an oil filter change and oil fill run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter 3 Filling the Oil Sump Add new oil through the oil filler cap on the top of the engine or through the side oil fill After refilling run the engine for a few moments while checking the oil pressure Make sure there is no leakage around the new oil filter or from the oil drain system and stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the high mark on the dipstick should the engine require additional oil A WARNING Used engine oil contains harmful contaminants Avoid prolonged skin contact Clean slein and nails thoroughly using soap and water Launder or discard clothing or rags containing used oil Discard used oil properly Engines Generators 21 GLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid When PREHEAT is pressed at the control panel this solenoid should click on and the glow plug should begin to get hot INSPECTION To inspect the plug remove the electrical terminal connec255tions then unscrew or unclamp each plug from the cylinder head Thoroughly clean each plugs tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits While cleaning examine the tip for wear and burn erosion if it has eroded too much replace the plug TESTING An accurate way to test glow plugs is with an ohmmeter Touch one prod to the glow plugs wire connection and the other to the body of the glow plug as shown A good glow plug will have a 10to 15ohm resistance This method can be used with the plug in or out of the engine You can also use an ammeter to test the power drain 8 to 9 amps per plugA WARNING These glow plugs will become very hot to the touch Be careful not to burn your fingers when testing the plugs Reinstall the plugs in the engine and test them again The plugs should get very hot at the terminal endwithin 20 to 25 seconds If the plugs dont heat up quickly check for a short circuit When reinstalling the glow plugs use antiseize compound on the threads Glow Plug Tightening Torque 7 11 IbH 10 15 kgmA WARNING 00 not keep a glow plug on for more than 30 seconds TERMINAL END Tightening torque JO 15 mkg 7 llftlbTIP GLOW PLUG THE OHMMETER TEST Engines Generators 20 FUEL SYSTEM DIESEL FUEL Use No2 diesel fuel with a cetane rating of 45 or higher Do not use kerosene or home heating fuel FUEL FILTERWATER SEPARATOR A primary fuel filter of the water separating type must be installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine Most installers include a fuel filterwater separator with the installation package as they are aware of the problems that contaminants in the fuel can cause A typical fuel filterwater separator is illustrated below This is the Rayeor Model 500 MA Keep in mind that if a water separator type filter is not installed between the fuel supply tank and enginemounted fuel system any water in the fuel will affect the fuel pump engine filter and injection equip255ment The owneroperator is responsible for making certain the fuel reaching the engines injection equipment is free of impurities This process is accomplished by installing and maintaining a proper fuel filterwater separator TYPICAL FUEL FILTER The fuel injection pump is a very important component of the diesel engine requiring the utmost care in handling The fuel injection pump has been thoroughly benchtested and the owneroperator is cautioned not to attempt to service it If it requires servicing remove it and take it to an authorized fuel injection pump service facility Do not attempt to disassem255ble and repair it The only adjustment the servicing mechanic should make to the fuel injection pump is the adjustment for engine idle speed see IDLE SPEED ADJUSTMENT under ENGINE LIFT PUMP Periodically check the fuel connections to and out of the pump and make sure that no leakage is present and that the fittings are tight and secure The DC ground connection at one of the pumps mounting bolts should be clean and well secured by the mounting bolt to ensure proper pump opera255tions When energized thru the preheat circuit the fuel lift pump will purge air from the fuel system and provide a continuous flow of fuel as the engine is running TO FUEL FILTER FUEL LIFT PUMP FUEL FILTERS INCOMING FUEL GROUNO The fuel injection pump and the fuel injectors are precisely manufactured and they must receive clean diesel fuel free from water and dirt To ensure this flow of clean fuel the fuel must pass through at least two fuel filters a fuel filterwater separator and the engines spinon fuel filter Visually inspect clean and change these filters according to the maintenance schedule in this manual A WARNING Shut off the fuel valve at the tank when servicing the fuel system Take care in catching any fuel that may spill DO NOT allow any smoking open flames or other sources of fire near the fuel sys255tem when servicing Ensure proper ventilation exists when servicing the fuel system LOOSEN FITTING WHEN PRIMING FILL FILTER Changing The Fuel Filter 1 Shut off the fuel supply 2 Loosen the fuel filter turning with a filter wrench Place the used filter in a container for proper disposal 3 Using a rag wipe clean the sealing face on the housing bracket so the new filter can be seated properly 4 Lightly oil the sealing Oring on the new filter To rein255stall tum the filter assembly carefully until the oring contacts the sealing surface of the housing bracket Tum 23 further with the filter wrench 5 The keyon preheat sequence will operate the fuel lift pump and quickly fill the new filter It is also possible to hand prime the filter using the lever on the top 6 Run the engine and inspect the filter for fuel leaks Engines Generators 19 tearing AdobeUCSa vital circulated around parts SYSTEM DESCRIPTION Westerbeke marine diesel engines are designed and equipped for fresh water cooling Heat produced in the engine by com255bustion and friction is transferred to fresh water coolant which circulates throughout the engine This circulating fresh water coolant cools the engine block its internal moving parts and the engine oil The heat is transferred externally from the fresh water coolant to raw water by means of a heat exchanger similar in function to an automotive radiator Raw water flows through the tubes of the heat exchanger while fresh water coolant flows around the tubes engine heat trans255ferred to the fresh water coolant is conducted through the tube walls to the raw water which is then pumped into the exhaust system where finally it is discharged overboard In other words the engine is cooled by fresh water coolant this coolant is cooled by raw water and the raw water carries the transferred heat overboard through the exhaust system The fresh water coolant and raw water circuits are independent of each other Using only fresh water coolant within the engine allows the cooling water passages to stay clean and free from harmful deposits FRESH WATER COOLING CIRCUIT NOTE Refer to the ENGINE COOLANT section for the rec255ommended antifreeze and water mixture to be used as the fresh water coolant Fresh water coolant is pumped through the engine by a circu255lating pump absorbing heat from the engine The coolant then passes through the thermostat into the manifold to the heat exchanger where it is cooled and returned to the engine block via the suction side of the circulating pump ZINC ANODE267 DRAIN DRAIN PETCOCK When the engine is started cold external coolant flow is pre255vented by the closed thermostat although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheatingAs the engine warms up the thermostat gradually opens allowing full flow of the engines coolant to flow unrestricted to the external portion of the cooling system Coolant Recovery Tank A coolant recovery tank allows for engine coolant expansion and contraction during engine operation without any signifi255cant loss of coolant and without introducing air into the cool255ing system This tank should be located at or above the engine manifold level and should be easily accessible CHANGING COOLANT The engines coolant must be changed according to the MAINTENANCE SCHEDULE If the coolant is allowed to become contaminated it can lead to overheating problems A CAUTION Proper cooling system maintenance is critical a substantial number of engine failures can be traced back to cooling system corrosion the engine coolant by loosening the drain plug on the engme block and opening the manifold pressure cap Flush the system with fresh water then start the refill process NOTE The drain petcock on the heat exchanger should also be used to help drain engine coolant COOLANT PUMP THERMOSTAT HOUSING INCOMING RAW WATER Engines Generators 15 AdobeUCSD D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D 5 panel is energized gauges are fuel lift pump is priming the start motor is cranking the abnormal noise Turn the FOR INITIAL STARTUP PRESTART INSPECTION Before starting your engine for the first time or after a pro255longed layoff check the following items D Check the engine oil level Add oil to maintain the level at the high mark on the dipstick D Turn on the fuel supply then check the fuel supply and examine the fuel filterwater separator bowl for D Check the transmission fluid level NOTE Refer to the specifications pages in this manualfor fuel oil and transmission fluid types and quantities D Check the DC electrical system Inspect wire connections and battery cable connections Make certain the positive battery cable is connected to the starter solenoid and the negative cable is connected to the engine ground stud this location is taggedD Check the coolant level in both the plastic recovery tank and at the manifold NOTE If the engine has not yet been filled with coolant refer to the COOLING SYSTEM section of this manual D Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threaded connections and engine attachments D Examine the air inlet and outlet for air flow obstructions Good ventilation and an ample air supply are 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 throughhull and prime the raw water intake strainer Inspect the raw water supply OIL MANIFOLD CERTAIN IT IS PUSHED ALL THE WAY IN Engines Generators 8 COOLANT RECOVER TANK CHECK COOLANT HERE COOLANT PRESSURE CAP L COOLANT HERE IiilLOW AdobeUCSthat contains and add CAPTAIN CONTROL PANEL DESCRIPTION This control panel is equipped with a KEY switch an RPM gauge PREHEAT and START but255tons an INSTRUMENT TEST button and three indicator lamps one for ALTERNATOR DISCHARGE one for low On PRESSURE and one for high ENGINE COOLANT TEMPERATURE RPM GAUGE REGISTERS REVOLUTIONS PER MINUTE OF THE ENGINE AND CAN BE RECALIBRATED FOR ACCURACY FROM THE REAR OF THE PANEL WATER ALARM LIGHT START BUTTON WHEN PRESSED ENERGIZES THE STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME TIME The panel also includes an alann buzzer for low On PRESSURE or high COOLANT TEMPERATURE The RPM gauge is illuminated when the KEY switch is turned on and remains illuminated while the engine is in operation ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE FALLS BELOW 5 10 psi 04 07 kgemIN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 210260F 99260CIN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL PRESSURE REACHES 15 psi 11 kgemTHE ALARM WILL SILENCE TEST BUTTON WHEN PRESSED TESTS THE ALTERNATOR THE OIL PRESSURE AND THE COOLANT TEMPERA255TURE CONTROL CIR255CUITS WHEN PRESSED THE ALTERNATOR THE OIL PRESSURE AND THE WATER TEMPERA255TURE INDICATOR LIGHTS ILLUMINATE IN ADDITION TO SOUND255ING THE ALARM BUZZER KEY SWITCH PROVIDES POWER ONLY TO THE INSTRUMENT PANEL CLUSTER PREHEAT BUTTON WHEN PRESSED ENERGIZES THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL SOLENOID ON THE INJECTION PUMP AND THE ENGINES GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES255SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER255GIZES THE START BUTTON Engines Generators 6 AdobeUCSremain illuminated SERIAL NUMBER LOCATION The engines model number and serial number are located on a nameplate mounted on the side of the engines manifold The engines serial number can also be found stamped into the engine block just above the injection pump Take the time to enter this information on the illustration of the nameplate shown below as this will provide a quick reference when seeking technical information andor ordering repair parts 131 NOTE A carbon monoxide warning decal has been provided by WESTERBEKE Affix this decal in a visible location in the engine room UNDERSTANDING THE DIESEL ENGINE The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same The cylinders are arranged above a closed crankcase The crankshaft is the same general type as a gasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods and lubricating system Therefore to a great extent a diesel engine requires the same preventive maintenance as a gasoline engine The most important factors are proper ventilation and proper mainte255nance of the fuel lubricating and cooling systems Fuel and lubricating filter elements must be replaced at the time peri255ods specified and frequent checking for contaminants water sediment etcin the fuel system is also essential Another important factor is the consistent use of the same brand of high detergent diesel lubrication oil designed specifically for diesel engines The diesel engine does differ from the gasoline engine however in its method of handling and firing of fuel The carburetor and ignition systems are replaced by a single component the fuel injection pump which performs the function of both ORDERING PARTS Whenever replacement parts are needed always provide the engine model number and serial number as they appear on the silver and black nameplate located on the manifold You must provide us with this information so we may properly identify your engine In addition include a complete part description and part number for each part needed see the separately furnished Parts ListInsist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment SPARES AND ACCESSORIES Certain spares will be needed to support and maintain your WESTERBEKE engine Your local WESTERBEKE dealer will assist you in preparing an inventory of spare parts See the SPARE PARTS page in this manual For engine acces255sories see WESTERBEKEs ACCESSORIES brochure Engines Generators 4 AdobeUCSWe take benefit from help you AdobeUCSPARTS IDENTIFICATION MAN ASSEMBLY DC CHARGING ALTERNATOR WATER CDNNECTlDN COOLANT PRESSURE CAP DRIVE CRANKSHAFT PULLEY OIL DRAIN HOSE HEAT EXCHANGER LEFT SIDE PREHEAT SOLENOID 20 AMP CIRCUIT BREAKER HBW FILL WATER INJECTED EXHAUST ELBOW FILTER l AIR INTAKE SILENCER STARTER WITH SOLENOID REAR OIL COOLEIl OIL PRESSURE SENDOR L FILL MOUNT FILTER THERMOSTAT OOIIYIDLY ALTERNATOR FRONT HURTH TRANSMISSION RIGHT SIDE MANIFOLD ID PLATE REAR ENGINE BLOCK DRAIN PLUG TRANSMISSION SHIFT LEVER Engines Generators 2 AdobeUCS 32 Stop Solenoid INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information CODES AND REGULATIONS Strict federal regulations ABYC guidelines and safety codes must be complied with when installing engines and generators in a marine environment SIPHONBREAK For installations where the exhaust manifoldwater injected exhaust elbow is close to or will be below the vessels waterline provisions must be made to install a siphon255break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 20 above the vessels waterline Failure to use a siphonbreak when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and possible flooding of the boat If you have any doubt about the position of the waterinjected exhaust elbow relative to the vessels waterline under the vessels various operating conditions instaU a siphonbreak NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphonbreak can result in catastrophic engine damage Consult the siphonbreak manufacturer for proper maintenance EXHAUST SYSTEM The exhaust hose must be certified for marine use The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of the vessels hull A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators Is available from your WESTERBEKE dealer Engines Generators iv SAFETY INSTRUCTIONS 225 Do not wear loose clothing or jewelry when servicing equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in moving parts 225 Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at all times 225 Do not check fluid levels or the drive belts tension while the engine is operating 225 Stay clear of the drive shaft and the transmission coupling when the engine is running hair and clothing can easily be caught in these rotating parts HAZARDOUS NOISE A WARNING High noise levels can cause hearing loss 225 Never operate an engine without its muffler installed 225 Do not run an engine with the air intake 225 Do not run engines for long periods with their enclosures open A WARNING Do not wode on machinery when you are mentally or physically incapacitated by fatigue OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTAuATIONS Preparations to install an engine should begin with a thor255ough examination of the American Boat and Yacht Councils ABYCstandards These standards are a combination of sources including the USCG and the NFPA Sections of the ABYC standards of particular interest are H2 Ventilation Pl Exhaust systems P4 Inboard engines E9 DC Electrical systems All installations must comply with the Federal Code of Regulations FCRABYC NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their when installing your engine ABYC American Boat and Yacht CouncilSafety Standards for Small Craft Order from ABYC 3069 Solomons Island Rd Edgewater MD 21037 NFPA National Fire Protection Protection Standard for Motor Craft Order from NFPA 11 Tracy Drive Avon Industrial Park Avon MA 02322 USCG United States Coast GuardUSCG 33CFR183 Order from US Government Printing Office Washington DC 20404 Engines Generators iii i i SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully Most accidents are caused by failure to follow fundamental rules and precau255tions Know when dangerous conditions exist and take the necessary precautions to protect yourself your personnel and your machinery The following safety instructions are in compliance with the American Boat and Yacht Council ABYCstandards PREVENT ELECTRIC SHOCK A WARNING Do not touch AC electrical connections while engine is running or when connected to shore power Lethal voltage is present at these connections 225 Do not operate this machinery without electrical enclosures and covers in place 225 Shut off electrical power before accessing electrical equipment 225 Use insulated mats whenever working on electrical equipment 225 Make sure your clothing and skin are dry not damp particularly shoeswhen handling electrical equipment 225 Remove wristwatch and all jewelry when working on electrical equipment 225 Do not connect utility shore power to vessels AC circuits except through a shiptoshore double throw transfer switch Damage to vessels AC generator may result if this procedure is not followed 225 Electrical shock results from handling a charged capaci255tor Discharge capacitor by shorting terminals together PREVENT BURNS HOT ENGINE A WARNING Do not touch hot engine parts or exhaust system components A running engine gets very hot 225 Always check the engine coolant level at the coolant recovery tank A WARNING Steam can cause injury or death 225 In case of an engine overheat allow the engine to cool before touching the engine or checking the coolant PREVENT BURNS FIRE A WARNING Fire can cause injury or death 225 Prevent flash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters 225 Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death 225 Do not operate with the air removed Backfire can cause severe injury or death 225 Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the clean and free of debris to minimize the chances of fire Wipe up all spilled fuel and engine oil 225 Be aware diesel fuel will bum PREVENT BURNS EXPLOSION A WARNING Explosions from fuel vapors can cause injury or death 225 Follow refueling safety instructions Keep the vessels hatches closed when fueling Open and ventilate cabin after fueling Check below for fumesvapor before run255ning the blower Run the blower for four minutes before starting your engine 225 All fuel vapors are highly explosive Use extreme care when handling and storing fuels Store fuel in a area away from sparkproducing equipment and out of the reach of children 225 Do not fill the fuel tankswhile the engine is running 225 Shut off the fuel service valve at the engine when servicing the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other sources of fire near the fuel system or engine when servic255ing Ensure proper ventilation exists when servicing the fuel system 225 Do not alter or modify the fuel system 225 Be sure all fuel supplies have a positive shutoff valve 225 Be certain fuel line fittings are adequately tightened and free of leaks 225 Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment Engines Generators CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNING Exhaust gasses contain Carbon Monoxide an odorless and colorless gas Carllon Monoxide Is poisonous and can cause and death Symptoms of Carllon Monoxide exposure can Include DIzziness lauSlla Headache Throbbing In Temples Museular TwItching Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS BET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms pelSlst SBIIk medical attention Shut down the unit and do not restart until It has btien Inspected and repaired This WARNING DECAL Is provided by WESTERBEKE and should be Oxed to a bulkhead near your engIne or generator WE8TERBEKEalso recommends Installing CARBON MONOXIDE DETECTORS In the qualfslS of your vessel Thsyare Inexpenslvs and easily obtaInable at your local marins stOlB to 243 It IJ 1ft t o q litOPERATORS MANUAL MARINE DIESEL ENGINE 630 UR N NO045150 FIRST EDITION March 2001 WESTERBEKE j WESTERBEKE CORPORATION267 MYLES STANDISH INDUSTRIAL PARK I 150 JOHN HANCOCK ROAD267 TAUNTON MA 027807319267 TEL 15088237677 FAX 15088849688 WEBSITE Member National Marine Manufacturers Association AdobeUCS

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