Westerbeke 12B TWO Operator's Manual

OPERATOR'S MANUAL

WESTERBEKE 12B TWO

MARINE DIESEL

ENGINE

Publication # 37185

Edition

One

January 1988

....v- WESJ'ERBEKE

WESTERBEKE CORPORATION

AVON

INDUSTRIAL PARK, AVON, MA

02322.

TEL:

(617)

588-7700

SAFETY PRECAUTIONS

The

following symbols appear in this manual to call attention

to and emphasize conditions potentially dangerous to the

operator.

IWARNING\

The

above symbol is used in the manual to warn of possible

serious personal injury or loss of life.

CAUTION

The

above symbol is used

in

the manual to caution personnel

of possible

damage

to equipment

Read

the manual carefully and thoroughly before attempting

to operate the equipment. Know when dangerous conditions

can

exist and take necessary precautions to protect personnel

and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and moving and

hot

parts are potential hazards that could result in

serious personal injury or death.

Follow recommended proce-

dures

carefully.

Always operate

bHge

blowers for at least five minutes before

starting agasoline-fueled engine; ensure no gasoline fumes are

present before starting.

..

Prevent Electric Shock

Shut off electric power before accessing electrical equipment.

Use insulated mats whenever working on electrical equipment.

Make sure your clothing is dry,

not

damp

(particularly

shoes),

,and

keep your skin surfaces dry when handling

electrical equipment.

Remove wristwatch and jewelry when working on electrical equipment.

Do

not

connect utility shore power to vessel's AC circuits,

except

through

a shipAo-shore double-throw transfer

switch. Damage

to

vessel's AC generator

may

result if this

is

not

done.

Be

extremely careful when working on electrical com-

ponents. High voltage can cause injury or death.

• Exhaust Gases Are Toxic

Ensure that the exhaust system is adequate

to

expel gases

discharged

from

the engine. Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and

no

warping exists.

Be sure the

unit

and its surroundings are well-ventilated.

• Use Extreme Care When Handling Engine Fuel (A constant danger of explosion or fire exists)

Do not fill fuel tank(s) while the engine is running.

Do

not smoke

or

use an open flame near the engine or the

fuel tank.

• Do Not Alter or Modify the Fllel System

Be

sure all fuel supplies have a positive shut-off valve.

Be

certain fuel line fittings are adequately tightened and

free of leaks.

Make sure a

1ire

extinguisher is installed nearby and is

properly maintained.

Be

familiar with its proper use.

Ex-

tinguishers rated ABC

by

the NFPA are appropriate for

all

applications encountered

in

this environment.

• Use Extreme Care When Servicing Batteries

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a highly-explosive gas,

which can be ignited

by

electrical arcing or

by

a lighted

cigarette, cigar, or pipe.

Do

not smoke or allow an open

flame near the battery being serviced. Shut off

all electri-

cal equipment

in

the vicinity to prevent electrical arcing

during servicing.

• Ayoid Moving

E.a!:1l>

Do not service the unit while the unit is running; if a situation

arises

in

which it is absolutely necessary to make operating adjustments, use extreme care to avoid moving parts and hot exhaust system components.

Do not wear loose clothing or jewelry when servicing

equipment; avoid wearing loose jackets, shirts or sleeves,

rings, necklaces, or bracelets that

might

be caught

in

moving parts. Make sure

all attaching hardware is properly tightened. Keep protective shields and guards in their respective place at

all times.

Do

not check fluid levels or the drive-belt's tension while

the unit is operating.

Do not work on the

equipment

when mentally or physical-

ly

incapacitated

by

fatigue.

IMPORTANT

PRODUCT

SOFTWARE

DISCLAIMER

Product

software

of

all kinds, such as brochures, drawings, technical data, operator's and

workshop

manuals, parts lists and parts price lists (and other related information), instructions and specifications provided from sources other

than

Westerbeke, is

no!

within Westerbeke's control and, accordingly, is provided to Wester-

beke

customers

only

as a

courtesy

and service. WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CON-

TENT

OF

SUCH SOFTWARE, MAKES

NO

WARRANTIES OR REPRESENTATIONS WITH RESPECT

THERETO, INCLUDING

THE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF, AND WILL IN NO

EVENT BE LIABLE FOR ANY TYPE OF DAMAGES

OR

INJURY INCURRED IN CONNECTION WITH,

OR

ARISING OUT OF, THE FURNISHING

OR

USE OF SUCH SOFTWARE.

For example,

components

and subassemblies incorporated into Westerbeke's

products

and supplied by

others (such as engine blocks, fuel systems and components, transmissions, electrical

components,

pumps

and

other

products) are generally

supported

by

their manufacturers

with

their own software, and Westerbeke

must

depend

on

such software for the

design

01

Westerbeke's

own

product

software. Such software,

however,

may

be

outdated and

no

longer

accurate. Routine

changes

made

by

Westerbeke's suppliers, of

which

Westerbeke rarely has notice in advance, are frequently

not

reflected in the supplier's software until

after

such

changes

take place.

Weslerbeke

customers should also keep in mind

the

lime span between printings

of

Westerbeke product

software, and the unavoidable existence

of

earlier, non-current Westerbeke software editions in

the

field. Ad-

ditionally,

most

Westerbeke

products

include customer-requested special features that frequently

do

not in-

clude

complete

documentation.

In summation,

product

software provided

with

Westerbeke products,

whether

from Westerbeke

or

other sup-

pliers,

must

not

and

cannot

be relied

upon

exclusively as the definitive authority

on

the respective product.

It

not

only

makes

good

sense,

but

is imperative

that

appropriate representatives

of

Westerbeke

or

the sup-

plier in question be consulted

to

determine the

accuracy

and

currency

of

the

product

software being con-

sulted

by

the

customer.

1

Weslerbeke

Diesel

Engines

FOREWORD

Thank you for selecting a Westerbeke marine product for your

use.

We

at Westerbeke are pleased to have

you

as

a customer.

Read

this manual carefully and observe

all

safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjustment procedures are included herein so you can operate your equipment safely and properly, maintain the equipment at a high level of efficiency, and expect dependable performance and long service life

in

return.

Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke Service Organization

is

trained to provide the support necessary

to

ensure long-term dependable perfor-

mance.

If,

within

60

days of submitting the Warranty Registration Form for your unit, you have not received a Cus-

tomer Identification Card (see below) registering your warranty, please contact the factory in writing with

Model information, including the engine's serial number and commission date.

from:

WESlER8EKE

CORPORA

liON

AVON

INDUSTRIAL

PARK

AVON,

~A

02322

'""fiI\T

I WESTERBEKE

~

;;;:.:~;:;:;:'.

::::;;,7~:;_::;;:

~:,~

~~~;,:=-""

CUSTOMER

IDENTIFICATION

Adall

Smith

Mail

To:

85 Maple

Stre-et

Alden,

1M

12234

Model N

12

TWO

Set.

•

1234(706

EJCpiree

7(7/88

""

....

Inspection of Equipment

The engine

is

shipped from the factory mounted securely and properly crated. Accessory equipment

is

shipped

in

a separate small box, usually packed within the engine's crate.

Before accepting shipment of the engine from the transportation company, the crate should be opened and

the contents inspected for concealed damage.

If

either visible or concealed damage

is

noted, you should

require that the delivery agent sign "Received

in

damaged condition" on the proper delivery receipt. Also

check the contents of the shipment against the packing

list and make sure that the proper notation

is

made

if

any discrepancies exist. These noted discrepancies are your protection against loss or damage. Claims

concerning loss or damage must be made to the carrier, not to the Westerbeke Corporation.

Westerbeke Diesel Engines

2

TABLE OF CONTENTS

Section ..........................................................................

Page

W 12B TWO MARINE DIESEL ENGINE

GENERAL SPECIFICATIONS ............................................ 7

W 12B

TWO SYSTEM SPECIFICATIONS ......................... 8

INSTALLATION CHECKS .................................................

10

PREPARATION FOR STARTING .....................................

21

DESCRIPTION

OF

INSTRUMENT PANELS .................... 23

STARTING PROCEDURE ................................................. 26

STOPPING PROCEDURE ................................................ 28

FUEL

SYSTEM ................................................................. 30

ELECTRICAL SySTEM .....................................................

33

DC WIRING DIAGRAM # 36467 SHOWING

THE CAPTAINS PANEL WIRING ............................. 34 & 35

DC WIRING DIAGRAM

#36844

SHOWING

THE ADMIRALS PANEL WIRING ............................. 36 & 37

COOLING SySTEM .......................................................... 39

LUBRICATION SYSTEM .................................................. 47

HBW

50 TRANSMISSION ............................................... 50

BW 3 TRANSMISSION .................................................... 54

ENGINE TROUBLESHOOTING ....................................... 57

MAINTENANCE & ADJUSTMENTS ................................. 60

LAY-UP & RECOMMISSIONING ..................................... 67

TABLE

OF STANDARD HARDWARE

TIGHTENING TORQUES ...............................................

71

TORQUE SPECiFiCATIONS ..........................................

72

SPARE PARTS ................................................................. 73

INDEX ............................................................................... 74

3

Westerbeke Diesel Engines

GENERAL

Introduction

This manual contains the equipment operating procedures

as

well

as

additional information needed to help

the operator keep the equipment

in

proper working order. Study and follow the instructions carefully. A

planned maintenance program

is

included

in

this manual; adhering to the program will result in better equip-

ment performance and longer equipment

life. Proper diagnosis of a problem

is

the most important step to

satisfactory repair; therefore, a troubleshooting

table

is

included.

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

of the same general type as that of 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

impOltant factors are proper ventilation and proper maintenance of the luel, lubricating and cool-

ing systems. Replacement of fuel and iubricating filter elements at the time periods specified

is

a must, and

frequent checking for contamination (that

is,

water, sediment, or allege)

in

the luel system

is

also essential.

Another important factor

is

the use of the same brand of high detel·gent diesel lubricating oil designed specifi-

cally

lor

diesel engines.

Be

careful not

to

put gasoline

in

the diesel fuel tank(s). Gasoline does not have the

same lubricating

qualities as diesel fuel; consequently, gasoline in the fuel lines will damage components

in

the fuel lift pump assembly, fuel injection pump and injectors.

The diesel engine does differ from the

gasoline engine, however, in its handling and firing of fuel. The car-

buretor and ignition systems are done away with and in their

place are

two

components -the fuel injection

pump and the fuel injectors.

Ordering Paris

When contacting your Westerbeke dealer, parts distributor, or the factory concerning your Westerbeke unit, always provide the engine's

model and serial number, and transmission number

as

they appear on the black

and silver "Westerbeke" plate which

is

mounted on the engine's exhaust manrrold. When ordering parts for

your Westerbeke engine, be sure to insist upon Westerbeke factory packaged parts, because

"will fit"

or

generic parts are frequently not made to the same specifications

as

original equipment.

Note that component locations

in

the rnanual are referenced from the front of the engine which

is

the pul-

ley/drive belt end. (The flywheel/transmission end is the rear end.) Left and right sides are determined

by

the engine; imagine straddling the engine and facing in the same direction as the front of the engine: the left

side

is

at your left, the right side

is

your right.

Westerbeke engines and generator sets are thoroughly checked and given a

final run under various load conditions before leaving the factory. Test running the engine ensure dependable operation, long service, and a satisfied owner.

Care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel engine capable of many thousands of hours of dependable service. However, the manufacturer cannot control the

treatment the unit receives

in

the field. That part

is

up to the owner/operator.

Westerbeke

Diesel

Engines

4

W 12B TWO Marine Diesel Engine

Exhaust

Manifold

gOO

Exhaust

Elbow

Heat

Exchanger

Zinc

Anode

-----~

Gear

Shift

Lever

Fuel

Lift

Pump

Oil

Pressure

Swi

Fresh

Water

Fill

Cap

Lube

Oil

Dipstick

Fuel

Injection

Pump

Fresh

Water

Lever

Shut-off

Lever

Oil

Pressure

Sender

Lube

Oil

Drain

Hose

5

Wes!erbeke Diesel Engines

W 12B TWO Marine Diesel Engine

Fresh

Water

Fill

Cap

Lube

Oil

Fill

Fresh

Water

Air

Bleed

---"'0

Sea

Water

Pump

DC

Charging

Alternator

Lube

Oil

Drain

Starter

with

Sol

Westerbeke Diesel Engines

DC

Battery

Ground

Connection

6

Amp

DC

Circuit

Breaker

_Pretle"t

Solenoid

gOO

Exhaust

Elbow

eat

Exchanger

Gear

Dipstick

Oil

Filler

BW

Marine

Gear

Assembly

Adjustable

Engine

Isolator

W

1213

TWO MARINE DIESEL ENGINE

Engine Type

Governor

Valve Mechanism

Combustion Chamber

Bore

& Stroke

Piston Displacement

Firing

Order

Direction of Rotation

Maximum Torque (at

2700 rpm)

Compression Ratio

Compression Pressure

Valve

Seat Angle

Valve Clearance (engine cold)

Dimensions

Inclination

Dry Weight

Fuel Consumption

GENERAL SPECIFICATIONS

Diesel, lour-cycle, two-cylinder, fresh water cooled, vertical, in-line (12

hp

at 3600 rpm maximum)

Mechanical, centrifugal weight type

Overhead

Swirl

chamber

type

2.56 x 2.68 inches (65 x 68 mm)

27.52 cubic inches

(0.45 liters)

1-2

Clockwise, when viewed from the front

19

Ib-ft (2.83 kg-m)

25:1

455 psi (32 kg/cm

2

)

at 320 rpm

Intake 45

0

Exhaust 45

0

Intake 0.0098 inches (0.25 mm)

Exhaust

0.0098 inches (0.25 mm)

Height: 19.57 inches

(497.07 mm)

Width: 17.75 inches

(450.85 mm)

Length: 24.90 inches (632.46 mm)

Continuous 14

0

Temporary

250 (not

to

exceed

30

min.)

205 Ibs (92.9 kgs)

0.3 U.S.

gph

(1.14 Iph) running at

2500 rpm (approximate)

7

Westerbeke

Diesel

Engines

W 12B TWO SYSTEM SPECIFICATIONS

FUEL SYSTEM

Fuel

I njection Pump

I njection Timing

Nozzle

I njection Starting Pressure

Lift Pump

Fuel Filter (on engine)

Air Cleaner

Air

Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

Fresh Water Pump

Sea Water Pump

Sea Water Flow, at 3600 rpm (measured before discharging into exhaust

elbow)

System Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter

Sump

Capacity (includes filter)

Westerbeke

Diesel

Engines

Open flow, totally self-bleeding

No.2

diesel oil (cetana rating

of

45 or higher)

Nippondenso (Bosch M type)

25°

±

OS

BTDC (Static)

Throttle type

2275.2 psi

(160 kg/cm

2

)

12-Volt DC; lift capacity 6 ft (1.8 m)

Canister type, with replaceable element

Metal screen type - cleanable

27.0cfm

(O.77cmm)

Fresh water cooled block, thermostatically-controlled with sea water exchanger system

170

-190°

F (77 -

88°

C)

Centrifugal type, metal impeller, belt-driven

Positive displacement, rubber impeller, belt-driven

gpm

( Ipm) approximate

4.0 qts (3.78 liters)

Forced lubrication by gear

pump

Paper element, spin-on type

3.27 U.S.

qls

(3.1

liters)

8

W 128

TWO

SYSTEM

SPECIFICATIONS

Operating

Oil

Pressure

Oil

Grade

ELECTRICAL

SYSTEM

Starting Battery

Battery Capacity

Starting

Aid Starter Motor DC

No-Load Current Cold Cranking Current Alternator Regulator

TRANSMISSION

HBW50

BW3

Standard Gear

Ratio

Optional

Gear

Ratio Direction of Rotation Lubrication

Fluid

Sump

Capacity

Standard Gear

Ratio Direction of Rotation Lubricating

Oil

Grade SAE

Grade

Sump

Capacity

35 -55

psi

(2.46 -3.86

kglcm

2

)

API

specification

CC

or

CD

12-Volt,

35

A-H,

(-)

negative ground

(recommended)

(45

A-H

cold

areas)

90 -125

(Ampere-Hours)

12-Volt

sheathed

type glow plug

12-Volt,

1.2KW,

solenoid, actuated shift

60

Amps

at

11.5

Volts

(6500

rpm,

min.)

209

Amps

at

12

Volts

12-Volt

DC,

35

Amps

Internal regulator, built into alternator

14.4

Volts

DC

± 3 Volts

2:1

2.5:1

Right

handed

- standard transmission

Automatic Transmission

Fluid

(ATF)

Type A or Dexron

II

0.32

U.S.

qts

(0.3

liters) approximate

2.47:1 Right

handed - standard transmission

API

specification

of

CC

or

CD

SAE

20

or

SAE

30

exclusively

0.37

U.S.

qts

(0.35

liters) approximate

9

Westerbeke Diesel Engines

INSTALLATION CHECKS

General

Because the crafts in which Westerbeke engines are installed vary in design, installation procedures will vary according to your craft's specific design.

It

is

not the intent of this section

to

advise boatyards or installers

on

procedures alreadywell-developed and well-understood. However, it

is

important that the owner/operator

realize there are details of the installation which require periodic checks

to

ensure the best operating condi-

tions for the equipment and safe operating conditions for the personnel on board. Proper location and in-

stallation of the diesel engine

in

the vessel are of prime importance.

Factors

in

the installation that must be considered are ventilation,

to

aid

in

cooling and

to

provide air for

en-

gine combustion; exhaust system,

to

property discharge raw cooling water, quiet the exhaust and expel ex-

haust gas; cooling water supply; fuel supply; and electrical connections.

CAUTION

For safety reasons, the engine and transmission are NOT filled with lubricating oil

for

ship-

ment. Before leaving the factory, however, each engine with transmission

is

thoroughly tested

with oil

in

it. This testing, among other things, provides all internal parts with a coating of oil.

This

oil

acts

as

a preservative, providing reliable protection against corrosion for at least one

year

if

the engine and transmission are property stored.

Location

The location should be such that it

is

dry, and away from being splashed by bilge water

or

water from above.

The engine should be properly ventilated and accessible for minor servicing and repairs (access

for

major

repairs should be given consideration as

well). The location must be property ventilated

to

provide fresh air for engine combustion. The engine's lubrication oil sump dipstick, the fresh water and oil fills, and the transmission's dipstick and transmission or oil

fill port must be accessible.

riLL CAP

COOLANT

RECOVERY

___

COCKPIT

TANK

~

AL

T!RNATIi~~~~~i=;~;:;;;===::J'7

MOUN11NC

STIlAI"

POSITIONS

CABIN

INSTALLATION

ANGLE

MUST

HOT

EXCEED

14'

Please note that the engine's installation angle cannot exceed 14' from the horizontal plain.

Westerbeke Diesel Engines 10

Rigging lind lilting

The engine is fitted

w~h

lifting eyes. Rope or chain slings capable of supporting the engine's weight should

be attached

to

the eyes and the engine lifted by means

of

tackle attached to these slings. The lifting eyes

have been designed

to

carry the full weight

of

the engine; therefore, auxiliary slings are not required or desired.

CAUTION

Slings

must not be so short as to place signijicant sheer stress on the engine's lifting eyes. Strain placed on the engine's lifting eyes by the lifting sling must not be in excess of 10' from the vertical

plain.

ENGINE

SL:ING

LIFTING

~HC;LE

MUST

NOT

EXCEEO

10·

LIFTING EYE

The general rule in moving engines

is

to

see

that all of the equipment used

is

amply strong and firmly fixed

in

place. Move the engine a little at a time and

see

that

IT

is firmly supported. Eliminate the possibility of ac-

cidents by avoiding haste. Do

nollift

the engine

by

its propeller coupling, or pry against this coupling with

a crowbar, because excessive pressure of this type may distort the

coupling.

In

certain situations it may be necessary

to

lift the engine in positions other than the horizontal position. Cer-

lain situations exist

by

which the engine must be lowered endwise through a small hatchway which cannot

be made

larger. Under these conditions, if the opening

of

the hatchway is extremely narrow,

tt

is

possible

to reduce,

to

some extent, the outside dimensions of the engine by removing external components such

as

the alternator, the cooling system's piping, the heat exchanger, certain filters, the mounting lugs and other

obstructive equipment. This accessory equipment should be removed by a competent mechanic and special care should be taken to avoid damaging any exposed parts. In addition, be careful not to allow dirt from entering any opening created by the removal of equipment. Parts removed

should be returned to their respec-

tive position

as

soon

as

the engine has cleared the hatchway.

In case

it

becomes necessary

to

hoist the engine either front-end upwards

or

transmission-end upwards, the

attachment of

slings must be done carefully to avoid the possibility

of

damaging the parts on which the weight

may bear.

Special rigging work

is

best done by someone experienced and competent

in

handling heavy

machinery.

11

Westerbeke

Diesel Engines

Engine

Bolts

Bronze

or

stainless steel hanger bolts of appropriate size are recommended for use through the engine's

flexible mounts. Less preferred are lag screws because their hold on the wood

is

weakened every time they

are

moved, whereas the hanger bolts stay in position. If the nut on

top

of the hanger bolt

is

removed

to

allow

the engine

to

be lifted from its resting place, the hanger bolt itself remains in place as a stud. Consequent-

ly,

the bond between the hanger bolt and the wood

is

not weakened by the removal of the nut

or

the engine.

Foundation

for

the

Engine

A good engine bed contributes much toward the satisfactory operation

of

the engine. The engine's bed

must be rigidly constructed and neither deflect nor twist when it

is

subjected

to

the engine's weight

or

to

the

pressures that the boat may experience while operating

in

rough

seas.

The bed must keep the engine's

alignment within one

or

two

thousandths

of

an

inch

of

this position at all times. The bed has to withstand

the forward push

of

the propeller shaft which pushes against the thrust washer bearing which finally pushes

against the engine's bolts and bed.

In fiberglass hulls, we recommend that similar wooden stringers as in wooden hulls be formed, fitted, and then

glassed securely to the hull. This allows the hanger bolts

to

be installed firmly in the wood, thereby

reducing noise and transmitted vibration.

The engine support stringers must be as wide

or

wider than the engine mounting isolator. Isolator overhang

and/or rounded stringer surfaces are

detrimental

to

the isolators' ability

to

retain vibration.

Preformed fiberglass engine beds, when used, should be of sufficient thickness

to

properly support the engine and should be well-glassed to the hull when installed.

The temptation

to

install the engine on a pair of

fiberglass angle irons must be resisted. Such

construction will allow engine vibration to pass through

to

the hull. Flexible mounts require a firm

foundation against which they must act

if

they are to perform their function. When possible, follow bed design A and avoid bed design B (refer

to

the illustration).

Supports between the bed stringers, and extending from the stringers

to

the hull, may be required for proper support and to aid in the absorption of vibrations.

Westerbeke

Diesel Engines

GOOD

A

BAD

B

Note:

Avoid

excessive

height,

use

solid

stringer

construction

(Al.

12

Propeller Coupling

The propeller shaft coupling fitted

to

the transmission's output flange must transmit not only the power of the

engine

to

turn the propeller shaft and propeller, but must also transmit the thrust of the engine/transmission

either ahead

or

astern.

The

coupling bore should be carefully machined for a slight forced fit onto the shaft and

an

accurate mating

surtace for the coupling

to

the output flange of the transmission.

For

all engine models, a propeller half-coupling, bored to shaft size for the specific order,

is

supplied. The

coupling either has a keyway with set screws or

is

of the clamping type.

The

fOlWard

end of the propeller shaft has a long straight keyway. Any burrs should be removed from the

shaft's end. The

coupling should be a light drive fit on the shaft and the shaft should not have

to

be scraped

down

or

filed in order to get a fit. It

is

important that the key be properly fitted both

to

the shaft and to the

coupling. The key should fit the side of the keyway closely, but should not touch the

top

of

the keyway

in

the hub of the coupling.

If

driving the coupling over the shaft

is

difficult, the coupling can be expanded

by

heating it in a pail of boil-

ing water. The face

of

the propeller coupling must be exactly perpendicular to the centerline or axis of the

propeller shaft.

Propeller

The type and size of propeller varies with the gear ratio and must be selected to fit the application, based upon boat tests. To utilize the

full power

of

the engine, and

to

achieve ideal loading conditions, use a propeller

which will permit the engine

to

reach its full rated

RPM

at full throttle while under a normal load and while

it

is

moving the boat

fOlWard

through the water. (See pages

53

and

56.)

Alignment

of

the

Engine

The engine must be

exactly aligned with the propeller shaft

in

the proper fashion. No matter what material

is used

to

build a boat the material will be found to be flexible to some extent; hence, the boat's hull will

change its shape to a greater extent than

is

usually realized when the boat

is

launched and operated

in

the

water. Therefore, it becomes

extremely important to check the engine's alignment at frequent intervals and

to

correct any errors when they appear.

Misalignment between the engine and the propeller shaft often creates serious problems which are often

blamed on other areas suspected of causing the trouble. Misalignment will cause excessive bearing wear, rapid shaft wear and will, in many cases, reduce the life of the boat's hull by loosening the hull's fastenings.

A bent propeller shaft will have the exact effect as those just stated; therefore, a pertectly straight propeller

shaft is absolutely necessary. One particularly annoying result of misalignment may be leakage of transmis-

sion oil through the transmission's rear oil

seal.

If oil

is

leaking from this seal, check and make sure that the

coupling's alignment

is

within the limits prescribed on page 14.

Never attempt a final alignment with the boat on land. The boat should be

in

the water and have had

an

op-

portunity to assume its

final water form. The best time

to

pertorm the propeller shaft/transmission coupling

alignment

is

with the fuel and water tanks about half full and

all

the usual equipment on board, and after the

main mast has been stepped and the

final rigging has been accomplished.

13

Westerbeke

Diesel

Engines

Take plenty of time

in

making this alignment and

do

not

be

satisfied with anything less than perfect results.

The

alignment is correct when the shaft can be easily slipped backward and forward into the counterbore, and when a feeler gauge indicates

thaI the flanges come together at all points. The alignment between the propeller shaft

coupling and the engine's coupling

can

contain

an

error no greater than one thousandth

of

an

inch per inch of the coupling diameter. For

ex-

ample,

if

your propeller shaft coupling

is

three inches

in

diameter, the maximum error thaI can be allowed

in

the alignment

is

three thousandths of

an

inch

(.003).

I n making the final check for alignment, the engine's half

coupling should

be

held

in

one

position and the

alignment with the propeller

coupling tested with the propeller coupling

in

each

offour

positions

(A),

while rotaled

900 between each position. This test will also check whetherthe propeller's half-coupling

is

in

exact

alignment on its shaft. Then, keeping the

propeller coupling

in

one position, the alignment should be checked by rotating the engine's half-coupling in

900 increments,

checking dimension

A while

in

each

900 posi-

tion until the half-coupling

has

been rotated lull

circle.

The

engine's alignment should

be

rechecked

after the boat has been

in

service

lor

one 10

three weeks and,

If

necessary, perform the

alignment again. Usually it will

be

found that

the engine

is

no longer

in

alignment. This does

not mean

Ihat the work has been done im-

properly at first; rather,

it

means Iha! the boat

has

taken some time to take its final shape and

that the engine's bed and stringers have

probably absorbed some moisture.

It may

even

be

necessary

to

realign the coupling hal-

ves

again

at

a later time.

Weslerbeke Diesel Engines

14

.333

FEELER

GAGE

PROPELLER

SHAFT

Exhaust System

The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel. The system also discharges sea water which has passed through the engine's sea water circuit by mixing

it

with hot exhalJst gases. This mixing helps cool the exhaust gases and exhaust elbow and plumbing. The

ex-

haust system and the sea water supply to the exhaust must be configured

to

prevent the siphoning of

sea

water into the exhaust through the sea water cooling circuit and

to

prevent the entry

of

sea

water into the exhaust through the circuit's thru-hull discharge port. If not prevented, sea water entering through the discharge port can lill the exhaust system muffler and enter the engine's cylinders. This will prevent proper starting and possibly cause damage to

internal engine components.

The sea water

supply hose

to

the

exhaust system water injection elbow should be routed (looped) at least

12 inches above the vessel water line.

An

anti-Siphon break should be installed, when needed, at the top of

this

loop. The

top

of

the loop should be placed high enough above the vessel's water line so

as

to

remain

above the water

line when the vessel

is

underway, no matter what the angle of heel

or

roll may be.

InSUlale-;:;:~;::;;;;~;;::o7~18"

,

..

ENCINE

INSTALLATIONS

WITH

EXHAUST

MANI-

FOLD/WATER INJECTED-ELBOW MINIMUM

OF

6

INCHES

ABOVE

VESSELWATER

LINE.

-.

6·

ENGINE

INSTALLATIONS

WITH

EXHAUST

MANI-

FOLD/WATER

INJECTED

ELBOW

AT

OR

BELOW

VESSEL

WATER

LINE

1',,' I.D.

"

2'

1.0.

48"

m"

12"

mEn

The sea water supply thru-hull sea

cock

fittings must be of the flush-hull type. High-speed scoop type of fit-

tings should not be used as they tend to encourage siphoning.

The exhaust discharge from the water

lift muffler should be routed well above the water line then downward

to

the thru-hull discharge. This routing will prevent

sea

water entry if the thru-hull discharge fitting becomes

submerged when the

vessel heels or rolls while under way, or

is

subjected

to

following

sea

conditions.

Refer

to the figures shown above

lor

recommended exhaust system installations.

15

Weslerbeke Diesel Engines

Exhaust Back-Pressure

The exhaust discharge hose must be of adequate size and minimal run

to

prevent excessive exhaust back-pressure.

Exhaust back-pressure

should be checked before a gener-

ator

is

put into service. (Refer

to

the illustration.) Excessive

back-pressure will affect the engine's performance.

To measure

for

back-pressure, use a mercury manometer, a

pressure gauge, or a water

column. A boatyard or marine

mechanic

should have a manometer or a pressure gauge.

Measure back-pressure at the exhaust

elbow when the en-

gine

is

running at 3600 rpm. Back-pressure, as measured

by

a manometer, a pressure gauge,

or

water column, should not

be over the

following specifications:

NOTE: Other pressure gauges may be available

to

test

for exhaust back-pressure. Check with a competent

mechanic.

Refer

to

the pressure specifications below.

A water column can be made

by

taking a clear plastic tube

and taping one end of the tube

along a yardstick and fitting the other end of the tube with a 1/4 inch NPT (National Pipe Tap) pipe fitting.

Measure back-pressure at the exhaust

elbow when the en-

gine

is

running at 3600 rpm.

Dimension A cannot exceed 39 inches of water.

Back pressure,

as

measured

by

a gauge instrument, should

not exceed the following specifications:

3 inches of mercury

(0.104 kg/cm

2

)

39 inches of water in a water column

(.099

kg/cm2 at 4

0

C)

22

ounces psi

1 1/2 psi

..

"

Exhaust Elbow

n Exhaust

Mercury

Manometer

\

Excessive back-pressure can be caused by a small diameter exhaust hose, a small muffler, sharp bends

in the exhaust hose, improper fittings, water pockets, and a high volume of water in the exhaust system due to the

length of the exhaust discharge hose. The use of elbows and fittings in the exhaust discharge hose's

routing

should be limited since these will create flow restrictions and contribute

to

exhaust back-pressure.

The generator's exhaust system must be separate from any other engine's exhaust system. Dry portions

of

the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be

insulated to

hold in the heat.

Westerbeke

Diesel

Engines

16

Exhaust

System

Failures

When the engine's sea water is fed into an exhaust system so that the

full stream

of

this water strikes a sur-

face, erosion takes place. This erosion may cause premature failures. The proper design

of

either a water

jacketed

or

water injected 'Wet" exhaust system

to

prevent this problem requires that the sea water inlet

be

positioned

so

that the entering stream

of

sea water does not directly strike a surface. In addition, the velocity

of the entering sea water stream should be as low as possible, which can be achieved

by

having inlet fittings

as big in diameter as possible.

The best protection against exhaust system leaks is

to

routinely inspect the complete exhaust system. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating surrounding areas excessively.

If excessive heat is present, correct the situation immediately. If

you

notice a change in the

sound

or

appearance

of

the exhaust system, inspect the exhaust system and correct the cause.

Exhaust risers installed off the exhaust manifold should

not

exceed 8

Ibs

in total weight when rigidly con-

nected. Excessive weight and vibration can result in a manifold failure and/or the fracturing

of

the riser from

the manifold at

Its attachment. Dry portions

of

the exhaust connected

to

the manifold, which lay before the

water injected exhaust system,

MUST

be properly insulated

to

retain the exhaust heat within the exhaust pipe

IWARNINGI

Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines, carbon monoxide is present in diesel exhaust fumes in less concentration. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Some

of

the symptoms

or

signs of carbon monoxide inhalation

or

poisoning are as follows:

o Dizziness o Vomiting o

I ntense Headache o Muscular Twitching

o Weakness and Sleepiness o Throbbing in Temples

If

you

experience any

of

the above symptoms, get out into fresh air immediately.

Make sure there are

no

unnecessary objects suspended from any portion

of

the exhaust lines. Excessive

weight could cause deflection

or

distortion

of

the lines, resulting in damage

or

leaks. Inspect insulated por-

tions

of

the exhaust system

to

ensure there is no deterioration

of

the insulation.

Oil Drain

An oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front of the engine.

Oil may be drained from this hose

by

removing the

cap

and the discharge end of the hose from the support bracket and lowering the hose into a container. The hose cap fitting is 1/4 inch NPT (National Pipe Tap) and can be extended,

or

have a pump added, for easier removal

of

the old oil, if desired.

17

Westerbeke Diesel Engines

Connecting

Pressure Sensing Devices

10

Oil Galleries

Oil

pressure sensing devices, such

as

senders and switches, must not be connected to

an

engine's oil gal-

lery with the use of extended nipples

or

tees. The reason

is

simply that continued engine vibration causes

fatigue of the fittings used

to

make such a connection.

If

these fittings fail, the engine loses its oil pressure

and quickly seizes.

When additional sensing devices such

as

switches or sensors need

to

be installed that function on engine

pressure, these devices must be bulkhead-mounted and connected

to

the oil gallery using

an

appropriate

grade of lubricatirig oil hose. Any fittings used to connect the hose

to

the gallery must be

of

steel

or

malle-

able iron composition. Brass must not be used for this application.

Cooling

System

The engine

is

fresh water cooled by an engine-mounted heat exchanger. Sea water

is

used as the heat

exchanger's cooling medium. Sea water

is

pumped into the exchanger by a sea water pump, where it cools

the fresh water that circulates through 'the engine block, 'and

is

then injected into the exhaust discharge, car-

rying with

it

the heat removed from the engine's fresh water cooling system.

Sea

water should be supplied

to

the sea water pump through a flush-type hull fitting using a wire-reinforced

hose between the

thru-hull fitting and the sea water pump. The sea water should be directed through a

visual-type sea water strainer, which will trap debris before it reaches the sea water pump and the heat

ex-

changer, and then be delivered to the pump. Hoses routed from the thru-hull fitting

to

the strainer and to

the sea water pump should be wire-reinforced to prevent the hose from

collapsing while the engine is running (suction from the pump may collapse a non-reinforced hose). The sea water strainer should be mounted at or below the water line

to

make sure the sea water line remains primed.

CAUTION

DO NOT

use

a scoop-type thru-hull fitting as a means of supplying

sea

water

to

the engine.

Water pressure against this type of fitting, while the vessel

is

under

sail,

can push sea water

past the sea water pump's

impeller into the engine's exhaust system, filling

it

and the engine

as well. Flush-type, clear, thru-hull fittings are recommended and should be located on the

hull so

as

to be below the waterline during

all

angles of boat operation.

The use of common-type street elbows

is

not recommended for plumbing the

sea

water cir-

cuit. These generally have very restrictive inside diameters. Machine fittings are preferred.

Automatic

Alarm System

High Water Temperature Alarm

A high water temperature alarm has been

supplied with the instrument panel. If the engine's fresh water

coolant reaches 205' F (96' C), a switch located at the engine's thermostat housing area will close sound-

ing this alarm which will

emIT

a

continuous

signal. Refer to the "DESCRIPTION OF INSTRUMENT PANELS"

section of this manual for the location of the alarm

in

your engine panel, page

23.

Westerbeke Diesel Engines

18

Low Oil Pressure Alarm

A low oil pressure alarm switch

is

located off the engine's oil gallery, This switch monitors the engine's oil

pressure,

Should the engine's oil pressure fall to

10

-15

psi, the switch will close sounding this same alarm,

In

this event, the alarm will emit a pulsating signal. Refer

to

the "DESCRIPTION OF INSTRUMENT PANELS"

section

of

this manual for the location of the alarm in your engine panel, page

23,

Sea Water

Intake

System

Make sure the intake system (sea water cooling system)

is

in proper order. Check that the hull inlet,

sea

cock

and strainer are unobstructed, Sea cocks and strainers should be at least one size greater than the

inlet thread of the sea water pump, The strainer should be of the type that may be withdrawn

for

cleaning

while the vessel

is

at sea and should be mounted below the water line

to

ensure self-priming, Inspect the

sea water lines

to

ensure there are no collapsed sections, which would restrict water flow, Make sure there

are no air

leaks at any

of

the connections,

Fuel

System

The fuel system should be installed in such a manner as

to

allow the engine-mounted fuel lift pump

to

main-

tain a positive inlet pressure

to

the injection pump under all operating conditions, The minimum size of the

fuel supply line and fuel return line is 1/4 inch, inside diameter, and there should be a primary fuel filter in-

stalled between the fuel tank and the fuel lift pump, Only one fuel filter

is

installed on the engine, between

the mechanical fuel lift pump and the injection pump; this filter has a

replaceable filter element

The

fuel tank's fuel pickup tube should be clear and unobstructed,

No

screens

or

gauze strainers should be

incorporated in the

fuel pickup tube,

Make sure that the fuel supply and return lines are

securely anchored

to

prevent chafing and that all fittings

are sufficiently tightened

to

prevent leaking, Also make sure your fuel system has a positive shut-off valve;

know its location and

how

it operates,

NOTE: DO NOT use spring-loaded check valves in the fuel supply line in lieu

of

mechanical

shut-off

valves,

The fuel return at the tank should extend

down

into the tank in the same manner as a pickup tube, This prac-

tice

is

particularly important in installations where fuel tanks are below the engine's fuel system,

Ensure that the

fuel tank filler

is

properly sealed

to

prevent water entry should

it

become awash, The fuel

tank's vent should be routed so as

to

prevent water entry as well,

Be

sure there

is

a fire extinguisher installed near the unit and that it

is

properly maintained, Be familiar with

its use, An extinguisher with the NFPA rating of

ABC

is

appropriate for all applications in this environment

Electrical

System

The electrical system should be checked to ensure that all wiring harnesses are tied down properly with

clamps

or

plastic ties, spaced at intervals close enough to prevent chafing from vibration, Check

to

ensure

that

all the engine's harness connections are tight and that they are made

to

the appropriate terminals,

HI

Westerbeke Diesel Engines

IWARNINGI

Do not smoke

or

allow an open flame near batteries. Lead acid batteries emit hydrogen, a

highly-explosive gas. Turn

oft the emergency switch

in

the

pos~ive

line

of

battery.

Make sure the

pos~ive

( + ) battery connection

is

connected

to

the battery connection of the starting solenoid.

The negative

(-)

battery connection should be connected

to

the system ground (the engine block).

IWARNINGI

When servicing the battery

or

checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Battery acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

Check level and

spec~ic

gravtty

01

battery electrolyte

to

ensure maximum engine starting efficiency. Make

sure terminals are clean and tight.

Ventilation

The ventilation requirements

of

the engine include the following: combustion air is required for the engine's

cylinders and ventilating air is required to clear the bilges below the engine, as well as the compartment

in

which the engine is located,

of

potentially toxic and flammable diesel fumes. Refer to the "SPECIFICATIONS"

section of this manual

for

the W 12B engine's airflow requirements, page

8.

Westerbeke Diesel

Engines

20

PREPARATION FOR STARTING

This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold

or

warm), and stopping procedures. Follow the procedures as presented,

for

the conditions indicated, and

your

Westerbeke engine set will give you reliable performance and

long

service life.

Fill

your

engine with oil

up

to

or

near the upper limit on

the dipstick (the installation angle

may

have an effect on

the dipstick reading).

Select readily available lubricat-

ing oil with an

API

specification of CC

or

CD and an SAE

number

suitable

for

the temperature

in

your

operating area (see page 47). For the quantity of oil needed in this engine, refer

to

the "SYSTEM SPECIFICATION" section

of

this manual, page

8.

Fill the transmission

to

the

FULL

mark

on

the dipstick

with

the

correct

lubricant. (Refer

to

the "SYSTEM

SPECIFICATIONS"

section

of

this manual, page 9.)

Each

unit

is

supplied

with a coolant

recovery

kit

(#24977)

as

standard equipment,

to

which the following

applies:

UPPER

LIMIT

(I,EORMAL

LEVEL)

LOWER

LIMIT

A.

Remove the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling sys-

tem

wtth a mixture of water and antifreeze suitable

for

your

temperature zone. (See the "COOLING SyS-

TEM"

section of this manual, page 39.) Operate the engine and observe the coolant level in

the

manifold.

Maintain this level

10

the base of the filler neck. Once the engine reaches its operating temperature (170

- 1900 F), ensure that there is coolant flow

to

the domestic water heaters when installed.

Top

off the

cooling system and install the pressure cap.

B.

Make sure the plastic recovery tank is property mounted near the untt (with the bracket provided), in a

location where it can

be monitored and filled easily. The recovery tank should be mounted at manifold

level

or

above. In these installations that require

it,

the plastic recovery tank can be mounted below the

exhaust manifold's

level.

C.

Add coolant

to

the plastic tank aiter the engine has been started and operating temperature has been

reached,

to

ensure that all air is expelled from the manHold and the engine's cooling system. With the

manifold filled and the pressure cap installed, fill the

plastic recovery tank half full. Monitor daily and

add coolant as needed.

Fill the

fuel tank with a

good

grade

of

NO.2 diesel fuel and prime the fuel system

up

to

the engine (see page

31). When returning fuel is free of air, the engine's fuel system is bled and the engine is ready

to

start.

NOTE: When the PREHEAT

sw~ch

is depressed, the

glow

plugs

in

the cylinder head are ener-

gized; use the PREHEAT switch intermittently

to

prevent overheating the

glow

plugs.

Ensure that the Installation Checks have been made

in

accordance with those specified

in

the "INSTALLA-

TION CHECKS"

section

of

this manual (refer

to

page 10).

21

Westerbeke

Diesel

Engines

Description

of

Starting

System

Westerbeke diesel engines use electric starters assisted

by

glow

plugs for both normal and cold weather

starting. The figure

below shows a cross-sectional view of one cylinder. The

glow

plug is located in the com-

bustion chamber so that its

tip

is in the injector nozzle's spray path. When the

glow

plug is energized

by

the

PREHEAT button, the

plug glows red at the

tip

and assists in igniting the fuel. The result is a rapid start with

less wear on the starter.

This system is

common

to

Westerbeke Diesels. The start circuitry is designed so that the PREHEAT button

must be depressed for the time specified in the "Preheat" chart shown on page

26.

Then, while keeping the

PREHEAT button engaged, the

START button is depressed

to

crank the engine.

GLOW

PLUG

Combustion Chamber

NOTE: The START button will not energize unless the PREHEAT button is depressed. When depressing the preheat switch, we are activating the

glow

plugs in the cylinder head, so use

the preheat

Intermittently so as

not

to

overheat the

glow

plugs.

Westerbeke

Diesel

Engines

22

DESCRIPTION OF

INSTRUMENT

PANELS

Westerbeke offers

two

types of

control

panels as optional equipment

for

the

W 12B engine. Read

the

follow·

ing instructions that

apply

to

the

panel

you

purchased with your engine.

Captains Panel

General

This manually-operated control panel is equipped with a key switch, an

RPM

gauge, a PREHEAT and START

button, and an instrument test button along wtth a

low

oil pressure/high water temperature alarm. The

RPM

gauge is illuminated

when

the

key switch is turned ON and remains illuminated While the engine is in opera-

tion. The key switch and

the

three buttons serve

the

following functions:

1.

Key Switch: The Key Switch provides

power

only

to

the instrument panel cluster. Refer

to

the "STOP-

PING PROCEDURE"

section

of

this manual, page 28.

2.

PREHEAT: The PREHEAT button activates the alternator's regulator, the engine's

glow

plugs, and bypas-

ses

the

engine's oil pressure alarm switch. In addition, this button energizes

the

START button.

3. START: The START button, when pressed, energizes the starter's solenoid which cranks

the

engine.

This button will not operate electrically unless the

PREHEAT button is pressed and held at

the

81me

time.

4. Test Button: The Test Button, located above the key switch, tests the alternator,

the

oil pressure, and

the

water temperature control circuits. When this button is pressed,

the

alternator,

the

oil p""ssure, and

the

water temperature indicator lights illuminate in addition

to

sounding the alarm.

23

Westerbeke

Diesel

Engines

5.6Iarm:

The alarm is located above

the

lest

button and will sound if

the

engine's oil pressure falls below

15

psi. In this event, the alarm will

emil

apulsating signal. The alarm will also sound if

the

water

tempera-

ture in

the

fresh water cooling circuit rises

to

210'

F.

In this event,

the

alarm will emit continuous sig-

nal.

Admirals

Panel

General

This manually-controlled control panel is equipped with a key switch and an

RPM

gauge with

an

ELAPSED

TIME meter

which

measures the engine's running

time

in HOURS and in 1/10 hours. The panel also includes

a water temperature gauge which indicates

water

temperature in degrees Fahrenheit

(WATER'

F), an oil

pressure gauge which measures the engine's oil pressure in pounds per square inch

(OIL PSI),

and

a DC

control circuit voltage gauge which measures the system's voltage (VOLTS). All gauges are illuminated

when

the key switch is turned

ON

and remain illuminated while

the

engine is in operation. The panel also contains

two

rubber-booted push buttons, one

for

PREHEAT and one

for

START.

1.

Key Switch: The Key Switch provides

power

only

to

the instrument cluster. Refer

to

the

"STOPPING

PROCEDURE"

section

of

this manual, page 28.

2.

PREHEAT: The PREHEAT button activates the alternator's exciter,

the

engine's

glow

plugs,

and

bypas-

ses

the

engine's protective oil pressure switch. In addition, this button is energizes

the

START button.

3.

SI8BI: The START button, when pressed, energizes

the

starter's solenoid

which

cranks

the

engine.

This button

will

not

operate electrically unless the PREHEAT button is pressed and held at

the

same

time.

Weslerbeke

Diesel

Engines

24

NOTE:

An

alarm buzzer

is

supplied with every Admiral Panel. The installer

is

responsible for

electrically connecting the buzzer to the four-pin connection on the engine's electrical

har-

ness. The installer is also responsible for installing the buzzer in a dry location so that it will

be audible

to

the operator should it sound while the engine

is

running. The buzzer will sound

when the ignition key

is

turned ON and should silence when the engine has started and when

the engine's oil pressure rises above

15

psi.

25

Westerbeke Diesel Engines

STARTING PROCEDURE

1.

Place the transmission in the NEUTRAL position and advance the throttle

to

its full open position for a cold

engine, and partially open for a warm engine.

2. Turn the key switch

to

the ON position

(2

o'clock).

3.

Depress and hold the

PREHEAT

switch. Preheat according to the following chart:

Atmospheric Temperature

+410

F

(+5

0

C)

or

higher

+410

F

(+5

0

C)

to

+23

0

F

(_50

C)

+23

0

F

(-

50

C)

or lower

Limit of continuous use

Proper

glow plug function

is

indicated by a voltmeter drop

when the PREHEAT switch is depressed. This drop

will be

slight but discernible. If no voltage drop

is

noted, it may in-

dicate defective

glow plugs or a faulty preheat circuit (check

for loose connections).

While holding the

PREHEAT

button depressed, depress the

START

button. The starter motor will

run,

thereby cranking

the engine.

As

soon as the engine runs, release the

START

button and PREHEAT button. Check your instrumentation for proper engine operation. Ensure sea water discharge with exhaust discharge.

Should the engine not start when the

START

button

is

depressed for

10

to

12

seconds, release both buttons and

wait

30

seconds; repeat the previous procedure. Never run

the starter motor for more than

30

seconds at a time.

CAUTION

Preheating Time

Approx.

10

sec.

Approx.

20

sec.

Approx.

30

sec.

1 minute

Prolonged cranking intervals

without

the

engine starting can result in filling

the

engine-

mounted

exhaust system with sea water coolant. This

may

happen because

the

sea

water

pump

is

pumping

sea water

through

the

sea water cooling system

during

crank-

ing. This sea water can enter

the

engine's cylinder's

by

way

of

the

exhaust manifold

once

the

exhaust system fills. Prevent

this

from happening

by

closing

the

sea water

supply

thru-hull shut-off, drain

the

exhaust muffler, and correct

the

cause

for

the

exces-

sive engine cranking needed

to

obtain a start. Engine damage resulting

from

this

type

of

sea water entry is not a warrantable issue; the owner/operator

should

keep

this

in

mind.

Westerbeke Diesel Engines

26

Once the engine starts, run it at idle for a few minutes to warm up the engine and check instruments for proper oil pressure and battery charging

voltage. Never attempt

to

engage the starter while the engine

is

running.

NOTE: Some unstable running may occur

in

a cold engine, but this condition should smooth

out as the operating temperature of

170

- 190" F

(77 -88"

C)

is

reached.

27

Westerbeke Diesel Engines

STOPPING PROCEDURES

A manual pull type stop control (tee handle or knob)

is

provided by the installer in a location close to the

engine's controls. Know the location of this control before attempting

to

start the engine. To stop the en-

gine, pull out on this tee handle or knob fully and

hold it out until the engine comes to a complete stop. Push

back on this control

to

return it to the engine run position otherwise the engine will not restart.

With the engine stopped, turn the key switch

to

the OFF position

(12

o'clock). If the key switch

is

left ON,

the battery will discharge. The alarm buzzer will sound

in

the Admirals Panel but not in the Captains Panel

should the key switch be left

ON. The best method of preventing the battery from discharge

is

to

remove

the key from the key switch after stopping the engine.

CAUTION

DO NOT

attempt

to

shutdown the engine by turning the key switch OFF. The key switch only provides power to the instrument panel: the engine will continue running even if the key switch is

turned

OFF.

(An

optional key shut-off package

is

available, however. This option allows the operator

to

shut-off the en-

gine by turning the key switch

OFF which turns OFF an electrically run Fuel Run Solenoid. This electrical

shut-off option

is

installed at the factory upon the specific request/order

of

the purchaser.)

Engine Break-In

Procedures

Although your engine has experienced a minimum of one hour of test operations to ensure accurate assembly and proper operation

of

all systems, break-in time

is

required. The service life of your engine

is

de-

pendent upon how the engine

is

operated and serviced during its initial hours of use.

Your new engine requires approximately

50

hours of initial conditioning operation to break in each moving

part

in

order to maximize the performance and service life of the engine. Perform this conditioning careful-

ly, keeping

in

mind the following:

1.

Start the engine according to the "STARTING PROCEDURE" section found on page

26;

run the engine

at fast idle while checking that

all systems (sea water pump, oil pressure, battery charging) are function-

ing.

2.

Allow the engine to warm up (preferably by running at fast idle) until the water temperature gauge moves

into the

130-1400 F range.

3.

While using the vessel, run the engine at varying engine speeds for the first

25

hours.

4.

Avoid rapid acceleration, especially with a cold engine.

5.

Use caution not to overload the engine. The presence of a gray or black exhaust, and the inability of the engine to reach

ITS

full rated speed, are signs of an overload.

6.

During the

neX1

25

hours, the engine may

be

operated at varying engine speeds, with short runs at full

rated speed. Avoid idling the engine for prolonged periods of time.

Westerbeke Diesel

Engines

28

Breaking-in a new engine basically involves seating the piston rings to the cylinder walls. This cannot be accomplished by long periods of running at Idle,

nor

by early running at full speed.

Idle running may glaze the cylinder walls, resulting

in

excessive oil consumption and smoky operation. Ex-

cessive speed or heavy overloading,

especially with a cold engine, may cause scoring of the cylinder walls,

producing similar results.

As indicated above, operate the engine

in

moderation during the 50-hour break-in period. (On one hand

don't

baby the engine, but on the other hand, however,

don't

abuse it.)

Starting Under Normal Conditions

Follow the procedure below for normal starting of the engine:

1.

Check the engine and transmission lubricant levels and fill, if necessary.

2.

Make sure there

is

sufficient fuel on board. Keep fuel tank(s) as full as possible. Check the fuel filters

and water separators for the presence

of

contaminants and/or water. Drain and clean them as needed.

3.

Check the coolant level in the plastic recovery tank. Add coolant solution as needed.

NOTE: Excessive loss

of

coolant from the plastic recovery tank indicates a cooling system

leak. Check the entire cooling system and pressurize the system

to

locate the leak. In cases

of

excessive coolant loss, the system must be refilled as outlined under the "PREPARATION

FOR STARTING"

section of this manual, page

21.

4.

Check for oil and fuel leaks, particularly

if

signs of such leaks are found on the bottom of the engine or

below the engine.

Start the engine in accordance with the "STARTING PROCEDURE" instructions found on page

26,

and allow

the engine's operating temperature to reach 140 - 150' F before operating the engine underway.

Starting Under Cold Conditions

Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below when operating your engine in cold weather.

LUBRICATING OIL TURNS VISCOUS - Make certain that the lubricating oil used conforms with the ratings

for the prevailing atmospheric temperature. Refer

to

the "LUBRICATION SYSTEM" section of this manual,

page 47 for an atmospheric/oil viscosity specification table.

VOLTAGE ACROSS THE BATIERY TERMINALS

DROPS

- Make certain that the battery

is

fully charged to

minimize

voltage

drop

across the battery terminals.

THE

TEMPERATURE OF THE INTAKE

AIR

IS

LOW AND THE COMPRESSION TEMPERATURE DOES NOT

RISE

ENOUGH -Allow the glow plugs

to

operate sufficiently to aid

in

starting during the preheat period when-

ever the temperature of the intake air

is

low and when the compression temperature does not rise enough.

Refer

to

the preheat chart found

in

the "STARTING PROCEDURE" section, page

26.

29

Westerbeke Diesel Engines

FUEL SYSTEM

Diesel Fuel

Use

No.2

diesel fuel with a cetane rating of

45.

Never use kerosene

or

home heating oil.

I

n cold weather particularly, water vapor

is

produced by condensation when air

is

present

in

the fuel tank.

Keep

fuel tank(s) full and completely free of dirt and water.

Fuel Filters

A primary

fuel filter of

the

water

entrapment type must

be

installed

be-

tween the fuel tank and the engine.

Such a filter, shown here,

is

available

from your local Westerbeke repre-

sentative or your boatbuilder. This filter, adapted for

boatbuilder

use,

comes

complete

with

fittings for either hose or metal tubing. Mount it in

an

accessible place, inspect it often

and drain off water accumulation

fre-

quently.

If

a water trap type filter

is

not installed

between the

fuel lank and the engine-

mounted fuel system, any water

in

the

fuel system will tend to lay

in

the bot-

tom of the electric lift pump. Internal

metal

parts of the lift pump will rust.

Particles will pass on

to

filters and

eventually

to

the injection pump and

injectors with damaging results and

the

possibility of expensive repairs.

Remember, water damage

to

the fuel

system is

not

covered under the

Westerbeke warranty.

HOSE FITTING

INSTALLATION

INSTRUCTIOHS

1.

aotT

SEDI"ENII~AIER

IR~P

SECUR£l'

TO

A~

ACCESSIBLE

SIRUtlURE

SO

PDSIlIONEO

111M R RECHTICLE

TU

cueH

D~AIMAH

tAM

BE

PUUD

UWO[R

IT.

2,

IF

FUEL

IS

TO

BE

PIPED

VITH

COPPER.

O~

BUMn,

IURlM&,

USE

NUIS

~MD

FERRULES

PROVUED.

BE

$URE

TH

TUBING

PROJECts

1/4

ntH

THROUGH

UE

FEAQULE

BHORE

TI&HTEMIMG

THE

MUT,

Irr~~~§j~m

3.

IF

FUEL

15

TO

BE

PIPEO

nlW

HOS[,

USE

THE

TWO

UAGS

BIIRBEO

fIlTIH~5

AND

WASHERS

BUPPtIU.

BE

CERUU

IHAI

THE

HOSE

SELECHD

HAS

U~&ONAL

BRUO

INSERTED

ITO

ClIliS

011

U£

8ARB).

TlIU

IT

15

NEOPRENE

LIMED,

lIND

THIIT

IT

IS

!!~n

~PPRDUED.

•.

If

VAIn IS

PIIESENT

1M

IH[

FUEL,

IT

ULt

COLLECT

SlBWLY U THE

BOTTOI!

Of

THE

5EnINEMIER.

WilE.

THE

REI)

FLOAT

RIMG

REACMES

THE

~RAtM

LIME

OM

111£

PLum

Bon,

LOOStN

THE

BOllOM

CRAIN

PLUS

~NTlL

ALL

WAIU

RUMS

DUI.

5.

TIGHTEN

DRUN

PLUS

!ECUUtv

SO

MO

AIR

c~w

[NTH

THE

sun".

6.

EMERG12E

THE

run

PUIIP

TO

UrILl

IHE

BOWL.

In

addition, any gasoline in the fuel system will damage the engine's fuel lift pump assembly, as gasoline

does not have the same lubricating qualities as diesel fuel, as well

as

have a damaging effect on the injec-

tion pump and the injectors.

Although most boatbuilders supply a water trap/filter, some

do

not. Westerbeke offers a sedimentary/water

trap/filter as

an

optional extra at moderate cost. The filter

is

supplied with fittings for etther hose or metal

tubing fuel lines.

Westerbeke Diesel Engines 30

Priming

the

Fuel System

The

Westerbeke self-bleeding fuel system

is

semiautomatic

in

operation. The self-bleeding feature of the fuel

system allows for easy servicing of the fuel filters.

Simply remove the and replace the filter elements (take care in catching any fuel that may drain out of the fuel filtering assemblies) as described in the "Replacing the Fuel Filter

Elements" section below. Energize the

PREHEAT

switch and allow the electric fuel pump to

operate for

20

to

30

seconds

to

prime and bleed air from the system. (No fittings should

be

opened.)

Then proceed to start the engine as you normally would. II the engine does not start, stop and wait a few moments, and then repeat the bleed procedure as indicated above. When the

PREHEAT

switch

is

depressed,

the preheat elements (the glow plugs) are energized, so take care not

to

over heat them.

CAUTION

Prolonged

cranking

intervals

without

the

engine starting can result in filling

the

engine-

mounted

exhaust system with sea water coolant. This

may

happen because

the

sea

water

pump

is

pumping

sea water

through

the

sea water

cooling

system

during

crank-

ing.

This

sea water can enter

the

engine's cylinders

by

way

of

the

exhaust manifold

once

the

exhaust system fills. Prevent

this

from happening

by

closing

the

sea water

supply

thru-hull

shut-off, drain

the

exhaust muffler, and correct

the

cause

for

the

exces-

sive

engine

cranking needed

to

obtain a start. Engine damage resulting

from

this

type

of

sea water entry

is

not

a warrantable issue;

the

owner/operator

should

keep

this

in

mind.

Replacing

the

Fuel Filter Elements

While it

is

unlikely that the operator will be forced

to

ser-

vice the system at

sea,

the possibility does exist. There-

fore, it

is

recommended that banjo washers, injector

seat washers, electric lift pump filter and gasket, fuel

filter and gasket be carried on board at all times. Select the parts for your engine from the Parts List and purchase spares from your local Westerbeke Dealer

or

Distributor. For example, hardware kit #33093 includes replacement elements with gaskets (items

#9,

11,

26,

27,

28). If a leak should develop at a fuel banjo

or

seal-

ing washer location that cannot be remedied

by

a slight tightening of the filter cup retainer, replace the filter along with the

O-rings supplied with the new filter.

After the first

50

hours of operation, loosen ring #

30

and

discard filter element #

28.

Clean bowl #

29

and install

a new filter using new #

27

and

28

gaskets. Be careful in catching any fuel that may spill from within these

fuel filter assemblies. This same service

is

required of the # 9 filter element in the electric fuel lift pump.

Similarly, install a new # 9 filter element along

with a new #

11

gasket. The base of the electric fuel pump

is removed with the aid of an open end wrench. Twist the base off the pump's locking tabs and reinstall the base

by

twisting it back on the locking tabs. Place the wrench on the hex

nut

cast into the base.

NOTE: DO NOT over-tighten the filter cup retainer; excessive tightening can strip the soft

aluminum threads on the fuel filter assembly.

After the first

50-hour change, the change period may be increased to

200

hours or once per season.

31

Westerbeke Diesel Engines

Fuel Injection Pump

The illustration shown below

is

an exploded view of the W 128 TWO's fuel system. The fuel injection pump,

located at the lower right-hand corner,

is

one of the most important components

of

the diesel engine and,

therefore,

call s

for

the utmost caution in handling. Furthermore, the fuel injection pump has been thorough-

ly bench-tested and should not be tampered with.

Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump.

Other types of adjustments

or

repairs must be performed

by

a qualified injection service shop.

FUfl

SUPPLY

W 128 TWO's

Fuel

System

To obtain long and satisfactory service from the injection pump, always use fuel which

is

free from impurities

and maintain a good filtration and water separation system between the

fuel tank and generator engine. Ser-

vice this system regularly: the injection pump it saves may be your own.

Westerbeke Diesel

Engines

32

ELECTRICAL SYSTEM

Engine

12-Volt DC

Control

Circuit

The Westerbeke W 128 TWO propulsion engine has a 12-Volt DC electrical control circuit, as shown on the wiring diagrams which follow on pages 34

to

37.

Refer

to

these diagrams when troubleshooting or servic-

ing electrical components on the engine.

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 en-

gine electrical circutt.

Battery

Specification

The minimum recommended capacity

of

the battery used in the engine's 12-Volt DC control circuit is

90

-

125 Ampere-hours (minimum).

CAUTION

When quick-charging the battery with an external charger, be sure

to

disconnect the battery

cables from the battery. Leaving the charging

circutt connected while quick-charging will

damage the alternator's diodes.

Alternator

CAUTION

When testing the alternator circuit (charging

cirCUIT),

do

not use a high-voltage tester such as

a rnegger; damaged diodes could result.

During high-speed operation of the engine,

do

not disconnect the positive terminal

of

the bat-

tery from the B terminal

of

the alternator, nor disconnect the negative terminal

of

the battery

from

the ground.

When cleaning the engine

wtth a steam cleaner, be careful

to

keep steam away from the aller-

nator.

Refer

to

pages 34

to

37

for

the

two

electrical system wiring schematics (one is used

for

the Captains panel

and the other for the Admirals Panel).

33

Westerbeke Diesel Engines

DC Wiring Diagram #36467 Showing

the

Captains Panel Wiring

page

1 of 2

W'RI'V

DIt.(RAM

"

<V-i'

"'ATE~

""HER

GI,OWPlUGS

r[

,,~

Tf

,",p_

",'.',0".

50NOfR

~~K

Of""J'~O

'"

~~

,"

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~(c

bALTE~Nn

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.

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-,

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~

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",."

BLU'

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---

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-----------------------~

Westerbeke Diesel Engines

34

I

1

"

~I

---

.!I

-'

~

1

'I

1

----j--

I[l

FUEL

SO

••

1

LlI';Woo<

,.,..(

"OO[L~J

:

':~

~

PUMP

CAPTAIN PANEL

DC Wiring Diagram #36467 Showing the Captains Panel Wiring

page 2

012

r.;

'2VOC

SCHEMATIC

DIAGRAM

0(

-------'

CLOIJPU.lGS

II

~_-1

____

L;i~+'~"""""'-'~,,"_-'-_~LJ"'~"-1'~~

__

-j_

,

STA~T:

LTURN

)(Ev

TO

ON

POSITION.

THE

ALARt~

'WIn

SOUND,

Olt

PRESSURE

A~C

NOTES:

8ATTEI'I'f

CHA~GE

INDICATORS

WilL

LlGH~.

2_PUS~

PREHEAT

SW11CH FOP

15

Tv

GO

SECONDS

AS

REOUIR(D.

AlARN

I,,"L\..

STot,

:\VJHILE

CONTiNUING

TC

PUSH

PREKEAT

S""ITCH,PUSI;

THE

START

s

....

ncl-'

'<'LSC.

WHEN

nlE

ENGINE

STARTS

RELEASE THE START

SIo>IITC,",

ONLY

~

wl"l£!>I THE

OIL

PRESSURE

INDICATO>!

lA.Io(P GOES OUT RELEASE T

.....

E

PR[r-I[AT

$\oIITCI1

THIS

PROOUC':"

15

Pl'IOTECTEO

By A MANUAL

"'~SET

CIRCUIT

BREAK[P.

lOChT(t

Nt

..

!'>

THE

START[A.EXCES$lVE

CURR("l,

DAAIN

WILL

CAUSE

;'"'~

BREhKE;:'

10

TRoll'

AND T ...

E

ENGINE

WILL

SHUT

OOIo'N. "f).lE BUILOER/Q'..,rfllER

Mus~eE

SUI'lE

T""T

TNt:

INST>lUME~T

PANE,-.WIFlING

AN~

ENGINE ARE

IN5TA:llEC'

it

PRE\lENT

COr.:TAC'" @ETWEE:II EJ..EC'l'I<ICAl

DE\lICES

AND

SAlTwAT[-R,

2,AN

O~·OFf'

SW·ITCH S'"<OUlD

BE

INSTALLED

BET

.....

EEr.: THE

ElAnE""

A~C

5TA"-,E"

~C·

DISCONNECT

THE

SAnERV'

Ir-I

All

E~ERGENC)

ArlO

..

HEN

lEAlJlNG

TI1E

eOt-T t-S'

..

ITe,.

WIT" A CONTiNUOUS

-"AT!NG

OF

17:'

A~PS

r:-

12\10C

WILL

SERvE

iHIS

FUNCTtOr.

nns

5\.o11TCH

SHOULD NOT

BE

USEI) TO MAKE 0R BREAI( THE CIReUI'";'.

35

Westerbeke Diesel Engines

SEE

r,OTE?

DC Wiring Diagram #36844 Showing the Admirals Panel Wiring

page 1 of 2

GLOW PLUGS

12,3

<,ORe

DfP,NDIN(,

O~

NUMIlER

OF

O'uN[)ERS

PREHEAT

SOLENOID

0~

i~

WIRING

DIAGRAM

ALTERNATOR

{G

(35

A,

40 A, 50 A)

,---'-./':7-",5;

___

_

~

--~-Eii;-----

_'_'~_:_~_:_e

___

~r,;;--"#~,~,~e~ED"-

___

-"'I--"I,~

~~~Il

SENDER SWITCH I

!~-

r~

gj~

§~~

I

.,

""

#14LT.BLUE

I 1

-~

r-~

~i

~,

Wi

1.<l#14LT.BLUE

l~1

I

J/~-C'~e'-"E~sC:suC:eC:E~""---"I'-'-!

-'-I:

-'-Ii

--_-_-_-

; i

SWITCH

I I

~

I I I I

I--

I

~ij

p

til:

,

I _

~#2.:.Y~RED

__

'_1_

-i----IZ\-..."

.

__

-.L:"<_---------l-- --.:....-----,: "-,---1

(USE,D

ON SOME

MODELS)

1-

I

Ii'

\.-/

a I 1 I

111

j7i1

FUEL SOLENOID

('--~,-;:;--,---~!

i I

~

OIL

l~

~:~:-

(USEDINSOME

\~:

~'

I

,I

i PRESSURE I !

~:,

~.

'I

MODELS)

;i

! I

~.,

,I

~

SENDER i

I""':

~

STARTER

GROUND TO ENGINE

BLOCK

BATIERY

12 VDC

C,"Cu<T

~':-I-'-'-'I

[GRD,"'

1 )

I,

i,:;:

-:;;: 1 I

I BREAKER -=- Ii:

II

~~~~;'NE

i,

;

i-=-=>=r

NEUTRAL

I I

~:p.'

I

If')

SAFETY

SWITCH!

I I

"'-'

(USED ON SOME

MODELS)

-',

-'

u

Pl(;

's

/,-"

)~

g:g,~gi;;f~,g!g:

1:),

"-'>-'O'c;:'1:C'0~i

;:

;::;;';i;:;;;

;!I

-,

,-,

,i

" ,

3:

>-1

:.:

z:

tol

~:

;!

~I

~il

~!

'1<:

::

i

~

'1<;

~---

S21 (

,.

C 01

---~---

P2'C

~

c ~

----T~

!

i"e~

I'

i i (

'-'"

\"

""'Go,,,

"""'''J

\ F

iii

~\<GH'.

~G"~\~V"

I

, '

iiI..

c

---;;:';~--'~

H

I~'

-~,

,e

~"--'

,'"

1

Z~

k _

~\[IC~

/T~HOMETER

"[,["

I~'i

'-----.J

ADMIRAL PANEL

----~-,~,',

KEy

SWITCH

, ,

~-/

VOLTMETER

START

I

SWITCH

PREHEAT SWITCH

r~

~

no!;"

Westerbeke Diesel Engines 36

DC

Wiring Diagram #36844 Showing the Admirals Panel Wiring

page 2 of 2

SCHEMATIC DIAGRAM

-<-

12

VOLT

DC

START

r-;-:-'

SOL

t--------~

I t

STARTER

,,)------~

'---t------'-'---

PRE~EAT

SOl.I

'f'

II-

'

GLQWPLUGS

--

'-

---,

'------

i

l)iCB

I'

~20A

NOTE:

i I " 0."A"L T

_______

-<

,

I-~

i~CB~:

i~!

L;'10A

~,

',:

'i

lIFTPUMP

I 'P\----------.

1 I ' I •

FU~

SOL.

I!

I

'----""""+---_

I L

_____

/=

,

O.P

D.P. SNDR.

G'SW,

0

I

W.T. SNDR.

j

A

I

1.

THIS PRODUCT

IS

PROTECTED

BY

A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE

STARTER. EXCESSIVE CURRENT DRAIN

WilL

CAUSE THE BREAKER TO TRIP AND THE ENGINE

Will

SHUT DOWN. THE BUILDER/OWNER MUST

BE

SURE

THAT

THE

INSTRUMENT PANEL,

WIRING,

AND ENGINE

ARE

INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL

DEVICES AND

SALTWATER.

2.

AN ON-OFF SWITCH SHOULD BE

INSTALLED

BETWEEN THE BATTERY AND STARTER TO DIS·

CONNECT

THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT. A SWITCH WITH

A CONTINUOUS RATING OF 175

AMPS

AT

12

VOLTS

DC

WILL. SERVE THIS FUNCTION. THIS

SWITCH SHOULD

NOT

BE USED TO

MAKE

OR BREAK THE CIRCUIT.

3.

THE GRAY WIRE

AT

PLUG

#2

IS UNUSED AND SHOULD BE INSULATED.

37

Westerbeke Diesel Engines

The charging system consists

of

an

alternator with

an

internal voltage regulator,

an

engine-mounted circuit

breaker, a battery and connecting wires.

Because of the use

of

IC's (integrated circuits), the electronic voltage regulator

is

very compact and

is

built

into the rear bracket

of

the alternator.

Charging Voltage Test

If you suspect that the alternator

is

not producing enough voltage to charge the engine's battery, perform

the

following voltage test.

ALTERNATOR

[35

A.

40

R.

50

AJ

r-----f-----€~aJ::--\ - -

"I

I

Interconnections for Charging Voltage Test

1.

Using a voltmeter, connect the voltmeter's

red

wire clip to the B output terminal on the alternator. Refer

to the schematic shown above.

2.

Connect the other wire clip

to

a ground

on

the engine.

3.

Start the engine and increase the engine's speed

to

2000 rpm. Now record the reading given

by

the

voltmeter.

The voltage reading for a properly operating alternator should be between 13.5

to

14.5 volts. If your alter-

nator

is

over or under charging, have it replaced or rebuilt by a reliable service shop.

Note: Before removing the alternator for repair, ensure that 12-Volts excitation

is

present at

the R terminal should the above test show only battery voltage at the B output terminal.

Westerbeke Diesel Engines

38

COOLING SYSTEM

Description

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced

in

the

engine by combustion and friction

is

transferred

to

fresh water which circulates throughout the engine. This

circulating fresh water cools the engine block and its internal moving parts. The heat is transferred

external-

ly from the fresh water

to

sea water

by

means of a heat exchanger, similar in function to an automotive

radiator.

Sea

water flows through the tubes of the heat exchanger while fresh water flows around the tubes;

engine heat transferred to the fresh water

is

conducted through the tube walls

to

the sea water which

is

then

pumped into the exhaust system where finally itis discharged overboard.

In other words, the engine

is

cooled

by

fresh water, the fresh water

is

cooled by

sea

water, and the sea water carries the transferred heat over the

side through the exhaust system. The fresh water and

sea

water circuits are independent of each other.

Using only fresh water within the engine

allows the cooling water passages to stay clean and free from harm-

ful

deposits. The

two

independent circuits and their components are discussed in the following paragraphs.

Fresh Water

Circuit

NOTE: Refer to paragraphs A and B in this section for the recommended antifreeze and water mixture

to

be used as the fresh water coolant, and for information on filling the fresh water sys-

tem.

Fresh water is pumped through the engine

by

a belt-driven Circulating pump, absorbing heat from the engine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through the thermostat into the exhaust manifold, to the heat exchanger where

it

is

cooled, and then

is

returned to the

engine

block through the suction side

of

the fresh water circulating pump. When the engine

is

started cold,

external fresh water flow

is

prevented by the closed thermostat (although some fresh water flow is bypassed

around the thermostat

to

prevent exhaust manifold from overheating).

As

the engine warms up, the thermo-

stat gradually opens, allowing full flow of the engine's fresh water coolant

to

flow unrestricted to the external

portion of the cooling system.

A.

Fresh Water Coolant (Antifreeze) Mixture.

It

is

recommended that a freshwater and antifreeze mixture be used year-round. Water, when it freezes, expands sufficiently to split the heat exchanger and crack the engine block. A water/antifreeze mixture of proper concentration will prevent freezing (see page

40

for an antifreeze/water mixture chart).

Use soft water with few impurities, such as tap water (potable water) or rainwater. Never use hard or foul water. Use

of

hard water or water containing impurities will lead to the collection of scale in the engine and

heat exchanger which will reduce the

cooling system's efficiency.

Antifreeze

01

poor quality or without rust inhibitors will cause corrosion within the cooling system. Always

use antifreeze which

is

compatible with aluminum cooling system components and

is

made by a reliable

manufacturer. Never mix different brands

01

antifreeze.

Make sure that the

cooling system

of

the engine

is

well cleaned before adding antifreeze. Recommended an-

tifreeze for year round use

is

ZEREX or PRESTONE with rust inhibitors.

In order

to

control the concentration of the mixture, mix the antifreeze and freshwater thoroughly before ad·

ding it

to

the cooling system.

39

Weslerbeke

Diesel Engines

ANTIFREEZE CONCENTRATION DATA

Antifreeze Concentration

%

13

23

30

35

45 50 60

Freezing

Temperature

'F

23 14 5

-4

-22

-40

-58

('

C)

(-

5)

(-10)

(-15) (-20) (-30) (-40) (-50)

NOTE: It is advisable that an antifreeze concentration be selected on the basis of a tempera-

ture which

Is

about

10' F (5'

C)

lower than the actual atmospheric temperature expected.

B.

Filling the Fresh Water System

A coolant recovery tank kit

is

supplied with each Westerbeke diesel engine. The purpose of this recovery

tank

is

to allow for engine coolant expansion and contraction, during engine operation, Without the loss of

coolant and without introducing air into the

cooling system.

This coolant recovery tank should be installed at, or above, engine manifold level,

in

a location where it can

be easily monitored and where coolant can be easily added

if needed (see the figure below). A stainless

steel mounting bracket

is

supplied with each ktt along with a 3D-inch length of clear plastic hose and clamps

to connect the hose between the engine's manifold fitting

to

the hose spud on the base

of

the recovery tank.

FUNCTION

OF

MANIFOLD

PRESSURE

CAP

From

Coolant Tenk

COOLANT

RETRACTION

to

Coolant

Tank

COOLANT

EXPANSION

Coolant from the engine, when heated during engine operation, will expand, lifting the spring-loaded manifold

pressure cap, and enter the recovery tank by way of the hose connecting the recovery tank

to

the manifold.

When the engine

is

shut down and cools, a small check valve

in

the pressure cap

is

opened

by

the contrac-

tion of the engine coolant, allowing some of the coolant in the recovery tank to be drawn back into the

engine's

cooling system, free

of

air and without loss.

Westerbeke Diesel

Engines

40

COOLANT

RECOVERY TANI(

\

',:

" ','

.'

. ;

... ~ ',F

·'J·\i 'I"

,.

1,\\

'

, , \

I'

/,

, ,

"

P~IESS;UAE

CAP

UANIFOLD

Coolant Recovery Tank, Recommended Installation

Fill the fresh water system as follows:

1.

Remove the pressure cap from the manifold.

2.

Pour a clean, antifreeze mixture into the manifold and allow enough time for the coolant

to

fill the fresh

water cooling system.

3.

Start the engine and allow

it

to come up to its operating temperature. Monitor the coolant in the manifold

and add antifreeze coolant

as

air

is

expelled. Once

all

air

is

expelled from the system, fill the manifold to

the filler neck and install the pressure cap.

4.

Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway between the ADD mark and the MAX mark. Replace the plastic cap.

5.

Run

the engine and observe the coolant's expansion flow into the plastic recovery tank.

6.

Check for leaks between the pressure cap/filler neck and then plastic recovery tank. Stop the engine and allow it to cool. Coolant should be drawn back into the cooling system as the engine's temperature comes down.

7.

Add coolant to the recovery tank, as required, to top off the fresh water coolant system.

Thermostat

Generally, thermostats are of two types. One

is

simply a choking device which opens and closes

as

the

engine's temperature rises and falls. The second type has a bypass mechanism. Usually this

is

a disc on

the bottom

olthe

thermostat which moves downward to close off

an

internal bypass passage within the head.

Since 1980, each type of thermostat has a hole punched through

it.

The hole is a bypass

to

prevent the ex-

haust manifold from overheating during the engine's warm-up. Replacement thermostats must have this

design characteristic.

41

Westerbeke Diesel Engines

Sea Water

Circuil

The sea water flow

is

created by a belt-

driven, positive displacement, neoprene im-

peller pump. The pump draws sea water directly from the ocean through the sea cock and sea water strainer and passes the water to the heat exchanger's sea water inlet. The sea

water

passes

through

the

heat exchanger's tubes, from which heat from the fresh water system

is

absorbed, and then the

sea water

is

discharged from the cooling system overboard through the water-injected wet exhaust system.

NEW

AHODE

REPLACE

Zinc Anode Conditions

CL

EAN

OR

REPLACE

A zinc anode,

or

pencil,

is

located in the sea water cooling circuit within the heat exchanger. The purpose

of the zinc anode is

to

sacrifice itself to electrolysis action taking place in the sea water cooling circuit, there-

by reducing the effects of electrolysis on other components

of

the system. The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required. Spare anodes should be carried on board.

Sea Water

Pump

The

sea

water pump

is

a sell-priming, belt-driven rotary pump with a non-ferrous housing and a neoprene

impeller. The impeller

has

flexible vanes which wipe against a curved cam plate within the impeller housing,

producing the pumping action. On no account should this pump be run dry. There should always be a

spare

impeller and impeller cover gasket aboard

(an

impeller kit).

Sea

water failures occur when lubricant

(sea water)

is

not present. Such failures are not warrantable and the operator's are cautioned

to

ensure that

sea water flow

is

present at start-up.

Alternator

and Water

Pump

Drive Belt Tension

IWARNINGI

Never attempt

to

adjust the drive belt's tension while the engine

is

in operation.

CAUTION

Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and reduce the service

life of the fresh water pump and alternator shaft bearings. Excessive slack

or

the presence of oil on the belt can cause belt slipping, resulting in high operating tempera-

ture, as

well as insufficient alternator output.

Westerbeke

Diesel Engines

42

The alternator and water pump drive belt(s) is/are property adjusted if the belt can be deflected no less than

3/8 inch and no more than 1/2 inch

(10

mm,

12

mm) as the belt

is

depressed with the thumb at the midpoint

between the two pulleys on the longest span of the

belt

(See the figure below.) A spare drive belt should

be carried on board.

Alternator and Water Pump Belt Tension

43

I

Westerbeke Diesel Engines

Illustrated below

is

a typical Westerbeke engine's cooling system, Both fresh water and

sea

water flow through their independent cooling circuits, Refer to your engine's Parts List for part numbers and part descriptions if you need

to

order cooling system parts for your engine,

NOTE: When the remote expansion tank #24177

is

used, the plastic coolant recovery tank should be removed and discarded and its connection point on the exhaust manifold plugged with a 1/8

NPT

fitting,

COOLANT

RECOVERY

TANK

HEAT

WATER

INJECTED

£LBOW

SEA VATER

Westerbeke Diesel Engines

EXHAUST

MANIFOLD

OVERHEAT

ALARM

Typical Cooling System

44

WATER

THERMOSTAT

f

IICOMII'

SEA

VITEK

Domestic

Hot

Water

The 12B

TWO engine is equipped with

domestic hot water heater connections.

If the owner/operator wishes to connect a hot water heater, remove only the small hose that connects with the thermostat housing and the exhaust manifold and connect

to these hose connections the hoses that run to

the heater.

General: With the small hose removed, there remain

two

connecting points for

hoses

to

run to and from the water heater.

These connections, when plumbed correct-

ly,

should allow for a flow of heated engine

cooling

system water

to

and from the

domestic water heater without effecting the

operation of the engine's cooling system.

ATTACH

HOSE

REMOVE

THIS

HOSE

RUNNING

FROM

WATER

HEATER

ATTACH

HOSE

RUNNING

TO

WATER

HEATER

Installation: The heater should

be

mounted conveniently either

in

a high

or

low position

in

relation to the

en-

gine so that the connecting hoses from the heater to the engine can

run

in

a reasonably direct line without

any loops which might trap

air.

The connection made to the thermostat housing should connect

to

the lower

of the two connections on the water heater while the upper connection

on

the heater returns to the connec-

tion on the exhaust manifold. (Note:

Use

a good grade of wire reinforced 1 inch

1.0.

hose to plumb from the

engine's connections

to

the hot water heater.)

FLOW

FROM

ItERTER

INTO

ENGINE

IoiAMIFOLO

FLOW

I"

T".!..-

.............

::::::::::::.V

HEATER

-

THE

PRESSURE

CfH"

OM

TilE

REMOTE

EXPANSION

TlHIIC

MUST

BE

RATED

LOWER

IHAN

THE

PRESSURE

CAP

ON

THE

I-IANIFOLD.

REMOTE

EXPANSION

TANK

(TANI(

KIT ~ 24177J

ENGINE

I-IRHIFOU,)

PREIiIiURE

CRP

FLOW

BACI(

Hno

HEATER

COILS

ABOU(

PREGGURE

en

FLOW

INTO

HEAT[R

HEATER

COILS

BELOW

PRESSURE

CRP

ENGINE

FLOW

OUT

OF

£t(GIN£

The

illustrations shown above are Flow Control designs which

have

been adapted

to

operate with the single

pass manifolds installed on the

12B

TWO

diesel engine.

45

Westerbeke Diesel Engines

Hoses should rise continuously from their low point at the heater

to

the engine so that trapped air will rise

naturally from the heater

to

the engine. If trapped air

is

able rise to the heater, then an air bleed petcock

must be

installed at the higher fitting on the heater for bleeding air while filling the system. Avoid loops

in

hose runs which will trap air.

Note:

If any portion

of

the heating circuit rises above the engine's own pressure cap, then a

pressurized (aluminum) remote expansion tank

must be installed

in

the circuit

to

become the

highest point. The remote expansion tank's part number

is

24177. Install the remote expan-

sion tank in a convenient location such

as

in a sail locker so the fresh water coolant level can

easily be checked.

The cap on the engine mounted expansion tank should not be opened once the remote system

is

installed

and filled.

The hose connection from the heater

to

the remote expansion tank should be

rou1ed

and supported so as

to rise continuously from the heater

to

the tank, enabling any air in the system

to

rise.

Refer to the illustrations on the previous page.

Westerbeke

Diesel

Engines

46

LUBRICATION SYSTEM

Engine

Oil

For engine lubrication, use lubricating oil designated for diesel service. These oils are classified according

to

the

API

specifications Into service grades CA, CB, CC and CD. The use of CC

or

higher (CD) grades, made

by

well-known manufacturers is recommended. The oil selected should be used thereafter.

Engine

Oil

Viscosity

(SAE

Number)

Use an oil having a viscostty best sutted

to

the atmospheric temperature. Use

of

an all-season oil

SAE

10W-

30

with minimum

visCOSITY

change under different temperatures is suggested.

Atmospheric Temperature

68° F (20°

C)

or

higher

41° F (5°

C)

- 68° F

(20°

C)

41

° F(5°

C)

-

or

lower

Viscostty

SAE 30

or

1

OW-3~

SAE

20

or

1

OW-3~

SAE 10W-30

NOTE:

Do

not

use an engine lubricating oil wtth an SAE number greater than

30

in the engine.

Oil

Pressure

The engine's

011

pressure, during operation, is indicated by the oil pressure gauge on the Admiral Panel (see

page 24).

During normal operation, the oil pressure will range between 35 and 55 psi. At

Idle speed, the oil pressure

will range between

20

and 35 psi.

Atthetime

of

cranking, the oil pressure will rise proportionately with speed.

NOTE: A newly started, cold engine can have an oil pressure reading upwards of 60 psi. A warmed engine can have an oil pressure reading as

low

as 35 psI. These readings will vary

depending upon the speed at which the engine is running.

47

Westerbeke

Diesel

Engines

Engine

Oil

Change

(to

include

filter)

1.

Draining the Oil Sump

Discharge the

old oil through the sump drain hose (attached

at the front of the engine) while engine is still warm. Drain the

old oil completely, replace the hose

in

ITS

bracket, and replace

the end cap securely.

Always observe the

old oil as

IT

is removed. A yellow/gray

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 competent mechanic should

water be present in the oil.

Sea water present in the oil can

be the result

of

a fault in the exhaust system attached

to

the

engine and/or a siphoning through the sea water

cooling cir-

cuit into the exhaust,

filling

IT

up into the engine (refer

to

the

installation illustrations on page 15).

2.

Replacement

of

the Oil Filter

When removing the used oil filter, 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 remov-

ing it. This helps

to

lessen spillage. A small style automotive

filter wrench should be

helpful in removing the old oil filter.

Place some paper towels and a plastic bag around the filter

when unscrewing it

to

catch any all left in the filter. (Oil

or

any

other fluid on the engine reduces the engine's

cooling ability.

Please keep

your

generator's engine clean.) Inspect the old

oil filter as it is

ret110ved

to

make sure that the rubber sealing gasket came off with the old oil filter. If this rubber sealing gasket remains sealed against

the

engine block, gently

remove

it.

The replaceable cartridge-type oil filter requires

no

cleaning inside, so it

may

be properly disposed of.

When

installing the new oil filter element, wipe the filter

gasket's

sealing surface on the engine block free

of

oil and

apply a thin

coat

of

clean engine oil to the rubber gasket

on

the oil filter. Screw the filter onto the threaded oil filter stub,

and then tighten the

filter firmly by hand

~11(1\

\11111'\!II.!!!I!!IH\Il'T'~::i:;;·

II

.1

\'

I I

I':":"

.

'.

II

.'.

'.

..

i

'~

.II

: I :

:,:;;

.:

NOTE: Generic filters are not recommended, as the material standards

or

diameters

of

im-

portant items

on

generic parts might be entirely different from genuine parts. Immediately

after an oil filter cnange and oil fill, run the engine

to

ensure that the oil pressure Is normal and

that there are

no

oil leaks around the new oil filter.

Westerbeke

Diesel

Engines

48

3.

Filling the Oil Sump

Add fresh oil through the oil

filler cap on the valve cover (refer to the photographs on pages 5 and 6 for the

location of the oil

filler cap and lube oil dipstick). After refilling the oil, run the engine for a few moments while

checking the engine's oil pressure. Ensure there

is

no leakage around the new oil filter or from the oil drain system, and then 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.

49

Westerbeke Diesel Engines

THE HBW 50 TRANSMISSION

General

The HBW

50

transmission

is

equipped with a positively-driven, mechanically-operated helical gearing sys-

tem. The servo-operated

multiple-disc clutch requires only a minimum effort

to

change drives. This feature

makes the transmission

suitable for a single-lever remote control with a rod linkage, such as a Morse or Bow-

den

cable. For safety reasons, the transmission is NOT filled with transmission fluid for shipment. Before

leaving the factory, however, each transmission

is

thoroughly tested with fluid in the transmission. This test-

ing, among other things, provides

all internal parts with a coating of transmission fluid. This fluid acts as a

preservative, providing

reliable protection against corrosion

for

at least one year if the transmission is proper-

ly stored.

DIPSTICK/FIll

PORT

Lubrication

The HBW 50 transmission

is

an immersion-lubricated type. Fill the transmission up

to

or near the top

of

the

machined notch cut on the dipstick with approximately

0.32 U.S. quarts (0.3 Ikers) of automatic transmis-

sion

fluid (ATF).

Change the transmission fluid after the first

30 hours of engine operation and thereafter every 250 hours (or

once per year, minimum). The HBW

50 transmission has a drain plug for draining the old transmission fluid.

To ensure that most of the

old fluid

is

drained from the transmission, run the engine in NEUTRAL

for

ap-

proximately

10

to

15

minutes so the transmission fluid may warm and flow better from the transmission. This

transmission

fluid may also be removed by inserting a small tube through the dipstick opening (where the

transmission

fluid is added) and attaching a pump onto the tube so the old fluid may be sucked out.

Westerbeke

Diesel

Engines

50

The operating oil temperature must not exceed

266'

F (130'

C).

If this temperature

is

to

be

exceeded during

normal operation, an optional transmission oil cooler should

be

installed. Consult you local Westerbeke

Dealer for details on this cooler.

NOTE: To check the transmission fluid level, remove the dipstick and wipe off

all

transmission

fluid on the dipstick, and place the dipstick back

in

the hole where ~ was removed, making sure that the base of the dipstick's threaded portion rests on the transmission housing. Now remove the dipstick and

see

where the fluid measures on the dipstick. If the transmission's

fluid level lies below the notch, add enough transmission fluid

to

raise the level back up to the

notch. Do not overfill the transmission.

DO NOT screw the dipstick into this hole to check the transmission fluid level. Screw the dipstick into this hole only after

an

accurate reading of the fluid's level has been taken. Make

sure that the dipstick

is

screwed

in

before and while the engine

is

operating. Ensure that the

sealing washer

is

present.

~

_.....",I~

I

DRAIN

PLUG

TO

CHECK OIL LEVEL

TRANSMISSION

IN OPERATION

FLUID LEVEL

LING

HER

The Transmission drain plug

is

located directly below the dipstick and

is

the same size hex head as the

dipstick. This drain plug also has a sealing washer.

Alignment

Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious problems. Ensure that the alignment procedures outlined in the "Propeller

Coupling,"

the"

Propeller, "

and

the"

Alignment of the Engine" sections of this manual are followed, pages 13 and 14.

51

Weslerbeke Diesel Engines

Controls

The only controls required

to

operate the transmission

is

a single lever remote control cable. The cable

should be attached to the gear box lever using the cable bracket supplied with the

unit

Both the gear box

lever and the remote control lever must be in the NEUTRAL position when the cable

is

attached

to

the gear

box

lever. This allows the remote cable

an

equal throw distance to shift the gear box into

FORWARD

or into

REVERSE

from the NEUTRAL posttion without running out of cable. Allow approximately 1.18 inches

(1

3/16)

of cable throw from the NEUTRAL position on the transmission's gear box lever

to

the each of the

two

drive

positions.

NOTE: If the throw distance (or travel) of the remote cable

is

too

short, the gear box lever

cannot fully engage the transmission into

FORWARD

or

REVERSE.

In this situation, the

transmission's clutch plates will wear prematurely and the transmission will eventually fail.

Minimum

Travel (Inner

nole

uSed)

,

1,18"

N

118"

/

30mm

i I

, . 0

GD\

J 0 I j

----

~·-"'-.CC=-~

...

-=:·

TItto~~----~-~-~~-

~-~~,,'

.~~@-

-

7f-:

,:

J

G5

ii:'~!

/

"'j

t...-;.,

'"

" I "

,-

,

'I

I

I '

Shllt

Cable

AttaChment

Iram Rear

11

~--

,

o

020

tncnes

Shltt

Arm

Securing

Boll

NOTE: Excessive throw distance

in

the remote control lever

is

not detrimental to the transmission. Note that the position of the remote control lever should align with the NEUTRAL marking on its bracket when the transmission

is

really in NEUTRAL.

Shifting

To shift the transmission from NEUTRAL into FORWARD, exert a heavy

push

to the remote control lever. A

gentle throw may not carry enough force to actually shift the transmission's internal gears. A gentle throw

is

signalled by the transmission not engaging into the desired drive, Make sure the remote control lever

is

lubricated at lease once each operating season. Shift the transmission while the engine

is

running at 1200

rpm or below, The clutch pack within the transmission makes

an

audiable "clunk" when engaging into gear.

Westerbeke Diesel Engines

52

CAUTION

NEVER remove or loosen the four-bolt gear box lever cover from transmission. The position of this

plate and the actuating lever inside of the transmission has been finely adjusted at the

factory

to

ensure equal throw distance of internal mechanisms. Loosening of this cover's

capscrews voids the transmission's warranty.

Sailing Operation

The HBW 50 transmission can be left in its NEUTRAL position while sailing. Leaving the transmission

in

NEUTRAL while sailing alleviates unnecessary drag on the vessel because the propeller

is

able to freewheel

(spin). However, should the operator wish

to

stop the rotation of the propeller shaft while under sail, this can

be done by

placing the transmission into

REVERSE

to

lock the propeller shaft.

Service

If

any seal on the transmission shows signs of leaking, have the transmission looked at

by

a qualified Wester-

beke

Dealer. This problem, especially concerning the rear seal, is often contributed to an improper align-

ment of the transmission's coupling and the propeller shaft's coupling. Refer to the "Alignment

olthe

Engine"

section of this

manual, page

13.

Recommended

Propeller Size

Propeller

Recommendations

(using HBW

50 transmission

2:

1 reduction)

Propeller Recommendations

(using

optional HBW

50

transmission with

2.5:1

reduction)

2-

12

0 x 6 P - blade or

11

0 x 6 P -3 blade

Propeller should allow

the engine to reach

its

full rated

RPM

(3600 + 000 - 100) at full open

throttle while underway.

120

x 8 P

-tlade

or

12

0 x 6 P - 3 blade

Propeller should allow

the engine

to

reach

its

full rated

RPM

(3600 + 000 - 100) at full open

throttle while underway.

53

Westerbeke Diesel Engines

THE BW 3 TRANSMISSION

General

The

BW

3 transmission rotates opposite to the engine when the transmission

is

in

FORWARD

gear. When

the transmission

is

engaged in

FORWARD,

the input power

is

transmitted to the output shaft

by

helical spur

gears. When the transmission

is

engaged

in

REVERSE,

the input power

is

transmitted

to

the output shaft by

a high-performance roller chain. This feature makes the transmission suitable

for

a single-lever remote con-

trol with a rod linkage, such as a Morse or Bowden cable. For safety reasons, the transmission

is

NOT filled

with lubricating oil for shipment. Before leaving the factory, however, each transmission

is

thoroughly tested

with lubricating oil in the transmission. This testing, among other things, provides

all

internal parts with a

coating of lubricating oil. This fluid acts

as

a preservative, providing reliable protection against corrosion

for at least one year

if the transmission

is

properly stored.

Lubrication

The

BW

3 transmission

is

an

immersion-lubricated type. Fill the transmission up to or near the

top

of

the

machined notch cut on the dipstick with approximately 0.37

U.S.

quarts (0.32 liters)

of

etther

SAE

20Wj20

or

W30

engine oil. Do not mix

SAE

grades. Do not use multi-grade oils. Use

an

oil having

an

API

specifica-

tion of

CC, CD,

SC,

or

SE.

DIPSTICK/FIll

PORT

Change the transmission oil after the first

30

hours of engine operation and thereafter every

250

hours (or

once per year, minimum). The

BW

3 transmission has a drain plug for draining the old transmission fluid.

To ensure that most of the old oil

is

drained from the transmission, run the engine

in

NEUTRAL for ap-

proximately

10

to

15

minutes so the transmission oil may warm and flow better from the transmission. This

Westerbeke Diesel Engines

54

transmission oil may also be removed by inserting a small tube through the dipstick opening (where the transmission oil

is

added) and attaching a pump onto the tube so the old oil may be sucked out,

The operating oil temperature must not exceed

266' F (130' C), If this temperature

is

to

be exceeded

during normal operation,

an

optional transmission fluid cooler should be installed, Consult you local

Westerbeke Dealer for details on this cooler,

NOTE: To check the transmission fluid level, remove the dipstick and wipe off

all

transmission oil on the dipstick, and place the dipstick back in the hole where it was removed, making sure that the dipstick's rubber head

is

properly inserted into the oil port, Now remove the dipstick

and see where the oil measures on the dipstick, If the transmission's oil level lies below the

notch, add enough transmission oil

to

raise the level back up

to

the notch, Do not overfill the

transmission,

DO

NOT

force the dipstick into the oil port to check the transmission oil level. Excessive pres-

sure can ruin the dipstick, Make sure that the dipstick

is

properly inserted into the oil port

before and while the engine

is

operating,

Alignment

Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious problems, Ensure that the alignment procedures outlined in the "Propeller Coupling,"

the"

Propeller, " and

the"

Alignment of the Engine" sections of this manual are followed, pages

13

and

14,

Controls

The only controls required to operate the transmission

is

a single lever remote control cable, The cable

should be attached to the gear box lever using the cable bracket

supplied with the unit. Both the gear box

lever and the remote control lever must be in the NEUTRAL

pOSition

when the cable

is

attached to the gear

box lever, The shift cable when properly adjusted should

allow for an equal throw of the transmission shift

lever into FORWARD or

REVERSE

from the NEUTRAL position without running out of cable, Allow ap-

proximately 1 1/2 inches of cable throw from the NEUTRAL position on the transmission's gear box lever to

the each

of

the

two

drive positions,

Minimum

Travel

{mner hole

usedj

N

1

1/2 1 1/2

/

Shit!

Cable

AttaChment

tram

Rear

55

Westerbeke Diesel Engines

NOTE: If the throw distance (or travel) of the remote cable

is

too

short, the gear box lever

cannot fully engage the transmission into

FORWARD

or

REVERSE.

In this situation, the

transmission's internal gears will wear prematurely and the transmission may over heat.

NOTE: Excessive throw distance

in

the remote control lever

is

not detrimental

to

the transmission. Note that the position of the remote control lever should align with the NEUTRAL marking on its bracket when the transmission

is

really in NEUTRAL.

Shifting

To shift the transmission from NEUTRAL into FORWARD, exert a

heavy

push

to

the remote control lever. A

gentle throw may not carry enough force

to

actually shift the transmission's internal gears. A gentle throw

is

signalled by the transmission not engaging into the desired drive. Make sure the remote control lever

is

lubricated at lease once each operating season. Shift the transmission while the engine

is

running at 1200

rpm or below.

CAUTION

NEVER

remove or loosen the two-bolt gear box shift lever cover from transmission. The position of this plate and the actuating lever inside of the transmission has been finely adjusted at the factory

to

ensure equal throw distance

of

internal mechanisms. Loosening

of

this cover's

capscrews voids the transmission's warranty.

Sailing

Operation

The

BW

3 transmission should be left

in

its NEUTRAL position while sailing. Leaving the transmission in NEUTRAL while sailing alleviates unnecessary drag on the vessel because the propeller is able to freewheel (spin). However,

if the transmission

is

left

in

its

FORWARD

gear while sailing, the transmission will not be

damaged. (Leaving the transmission

in

NEUTRAL

is

just good sailing practice.)

Service

If

any

seal

on the transmission shows signs of leaking, have the transmission looked at by a qualified Wester-

beke Dealer. This problem, especially concerning the rear

seal,

is often contributed

to

an improper align-

ment

olthe

transmission's coupling and the propeller shaft's coupling. Refer to the "Alignment

01

the Engine"

section of this manual, page 13.

NOTE: Never loosen the four gear box lever cover screws, except in the course

of

qualified

servicing; this upsets critical adjustments. Disassembly of the transmission

in

the field

is

not

recommended.

If an overhaul or repair

is

needed, the work should be done by Westerbeke

or an authorized Westerbeke service center.

Recommended

Propeller Size

Propeller Recommendations

(using BW 3 transmission

2:1

reduction)

Westerbeke Diesel Engines

2-

12

D x 6 P - blade or

11

D x 6 P - 3 blade

Propeller should allow the engine

to

reach

its full rated

RPM

(3600 + 000 - 100) at full open

throttle while underway.

56

ENGINE TROUBLESHOOTING

Introduction The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the

probable causes of the problems, and the recommendations to overcome these problems.

Note that the engine's control

system (electrical system)

is

protected

by

a 20-Ampere manual reset circuit

breaker located on the rear lifting bracket.

Problem

Key switch

ON

but no panel or

test function.

PREHEAT switch

is

de-

pressed: no preheat

solenoid activation:

no electric

fuel pump or

alternator excitation.

Probable Cause

1.

Battery OFF.

2.

20 Amp circuit

breaker

is

tripped.

3. Loose battery cable connection

1.

Faulty solenoid,

connections or switch.

2.

Faulty connection or

tripped

10

Amp breaker

on the I terminal on the

preheat solenoid.

57

Verification/Remedy

1.

Turn Battery ON.

2.

Reset the breaker

by

pushing in the button.

3. Check the

+ connection

to

the starter and the -

connection

to

the ground

stud on the

bell housing.

1.

Connection for

12

volts

at

S terminal of the solenoid

is.

faulty.

1. Check the preheat switch.

2. Check for

12

volts at the

10

Amp breaker. Check

for

12

volts at fuel lift pump and at the R terminal on the alternator when the preheat

button

is

pushed.

Wes!erbeke Diesel Engines

Problem

8T

ART

switch

is

de-

pressed: no starter

engagement.

Engine cranks,

but does not start.

Failure

to

stop.

Westerbeke Diesel

Engines

ENGINE TROUBLESHOOTING

Probable Calise

1.

Connection

to

solenoid faulty.

2. Faulty 8T

ART

switch.

3. Faulty solenoid.

4. Loose battery

connection.

5.

Low batteries.

1.

Shut-off valve at

fuel tank.

2. Faulty fueling system.

to engine.

3. Air

is

in the fuel

system.

4.

Fuel pump

is

not

operating.

5.

Fuel filters are clogged.

1.

Mechanical

Run

linkage disconnected.

58

verification/Remedy

1. Check connection S at the

starter solenoid for

12 volts

with the switch depressed.

2.

Check

SWitch

with an

ohmmeter.

3.

Twelve volts

is

present

at the

S terminal of the

starter solenoid.

4.

Check battery connections

at both the

+ and - ground.

5.

Check battery charge state.

Low voltrage at the solenoid's S terminal with no activation.

1.

Return shut-off valve

to

its ON position.

Now

bleed

the

fuel system.

2. Check

for

fuel

3. Bleed the fuel system. Locate the

leak and correct

it.

4.

Check pump operation.

5.

Clean/replace filters.

1.

Stop engine by man-

ually moving the RUN

linkage

to

STOP.

That failing,

shut off

fuel and air.

Problem

Engine

Stops.

Battery runs down.

Probable

Cause

1.

Fuel starvation.

Fuel shu1-off is turned

OFF.

2.

Fuel pump is

inoperative

3.

Water is in the

fuel.

4.

Exhaust system is

restricted.

1 . Alternator

ou1pu1.

is low.

2.

Faulty alternator.

3.

Bad battery

connections.

59

YerificationlBemedy

1.

Check

to

see that the

shu1-off valve at the

fuel tank is

ON.

2.

Inspect the fuel pump for

12 volt and

to

see

if

it is

pumping.

3.

Pump water

ou1

of the

bottom

of

the fuel tank(s) and

change the fuel filters and

bleed the fuel system.

4.

Check exhaust system for

some type

of

blockage such as carbon buildup at the exhaust elbow.

Check

for a fault

in

the muffler. Check for a collapsed exhaust hose.

1.

Check drive belt tension.

Make an

Ou1pu1

check

wtth a voltmeter at the B + terminal

on

the alternator.

2.

Voltage leak through

the alternator when not operating.

3.

Connections are corroded

or

loose at the battery

orland

at

the engine.

Westerbeke

Diesel

Engines

MAINTENANCE AND ADJUSTMENTS

Introduction

This section contains a scheduled preventive maintenance program and several adjustment procedures the

owner/operator can perform without the benefit of sophisticated and expensive tools and instruments,

Preventive

Maintenance

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs,

Adherence

to

these schedules will ensure the equipment

is

maintained in the best possible condition and

that

it

will perform

to

expectations, Those items marked by

an

asterisk

(*)

are recommended to be per-

formed

by

an authorized dealer or distributor.

Daily (before each use)

1,

Check the oil sump level. Maintain the oil level

at

or

near upper level mark on dipstick,

2,

Check the coolant level in the plastic recovery tank, Maintain this level at

or

above the level marked

ADD,

3,

Check the transmission's lubricant level, and add additional lubricant as needed,

4,

Visually inspect the unit; check for loose bells, chafed or broken wires, loose brackets and fittings, damaged hoses, loose clamps, and other equipment not properly secured, This check should include the propeller shaft coupling to the transmission's output flange,

5,

Check the fuel supply, Fill tank(s) with a good grade

of

No, 2 dieselluel,

if

required,

6,

Check the primary filter/water separator. Drain and service

as

required,

(A

primary iilterjwater separator

is optional, but strongly recommended,)

7,

Check the engine's gauges or lights for proper oil pressure, operating temperature, and starting bat-

tery charging

voltage once the engine

is

operating,

8,

Check the alternator's output gauge (if installed) for proper DC voltage,

Monthly

Check the condition

of

the zinc anode in the heat exchanger's

sea

water

circuit

Clean or replace the anode,

as

required, Keep the area inside the heat exchanger clean

01

zinc anode debris,

Servicing After Initial

50

Hours

01

Operation

1,

Change the engine's lubrication oil and oil filter,

2,

Replace the fuel filter element in the electric fuel lift pump and

in

the optional water/sediment separator,

if

a separator has been installed,

Westerbeke Diesel Engines

60

*3. Torque the cylinder head boits.

*4. Adjust

valve clearances.

5.

Adjust the alternator and water pump drive belt tension,

IT

required.

6.

Lubricate the throttle, the

RUN

linkage cable, and the transmission's remote control cable.

7.

Change the transmission's transmission fluid

IT

your engine is equipped with a HBW 50 transmission, or

change the transmission oil

IT

your engine is equipped with a BW 3 transmission.

Servicing

After

Every

100

Hours

of

Operation

1.

Change the engine's lubrication oil and oil filter.

2.

Adjust the alternator and water pump drive belt tension,

IT

required.

3.

Check the transmission fluid

or

oil level.

Servicing

After

Every

250

Hours

of

Operation

1.

Replace the fuellilter elements in Ihe electric fuel lift pump and in the optional water/sediment separator.

2.

Change the transmission's transmission fluid

IT

your engine is equipped with a HBW 50 transmission, or

change the transmission oil

if

your

engine is equipped with a BW 3 transmission.

Servicing

After

Every

500

Hours

01

Operation

*1. Torque

the

cylinder head bolts.

*2. Adjust the valve clearances.

3.

Drain, flush, and relill the fresh water cooling system. The illustration

on

page 5 shows the heat ex-

changer and

the zinc anode location. The drain plug for the fresh water system is next

to

the zinc anode.

*4. Check the

condition

01

the starler motor drive pinion; lubricate the pinion.

5.

Check the

resiste!11ce

of the

glow

plugs. (.4

to

.6 ohms)

NOTE: Items highlighted by an asterisk

(*)

should be performed

by

a competent mechanic.

61

Westerbeke

Diesel

Engines

Servicing

After

Every

800

Hours

01

Operation

*1. Remove and check fuel injectors.

I njector spray pressure:

1991

psi +

140

psi

(140 kglcm

2

+

10

kglcm

2

)

Eliminate undesirable injection conditions including after dripping.

*2. Check the engine's compression pressure.

Remove each

glow

plug and

check

each

cylinder's compression pressure. The engine's

cranking speed

is

at 280 rpm.

Standard

Minimum

,

POOR

~~~f~~~:~_~.,~~~.

____

~[j)J\

GOOD

455

psi

(32

kg/cm

2

)

369.7 psi

(26 kglcm

2

)

{Maximum difference between cylinders: 35.5 psi (2.5 kg/cm

2

)

*3. Check the battery-charging alternator for proper operation.

*4. Check the tightness

of

bolts, nuts, and clamps.

Servicing

After

Every

1000

Hours

of

Operation

1.

Remove, clean, and pressure test the primary heat exchanger.

(A

local automotive radiator shop should

be able to clean and test the heat exchanger.)

NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning

be performed more often than every

1000 hours.

*2. Check the injection pump's timing.

Westerbeke Diesel

Engines

62

Torquing Cylinder Head Bolts

Tighten the cylinder head bolts according to the sequence shown in the illustration shown

to

the right. Make

sure the engine

is

cold when this

is

done. Loosen one head bold one-half turn and then tighten

it

between

56

to

59

Ib-ft (7.8

to

8.2

kg-m). Then proceed to the next head bolt

in

the sequence numbering shown.

Valve Clearance Adjustment

NOTE: Retorque the cylinder head bolts before adjusting the engine's valves.

1.

Remove the rocker arm cover.

2.

Position the No.1 piston at Top Dead Center

(TDC)

of its compression stroke. To

do

this, align the timing

mark on the gear case with that on the crankshaft pulley (refer

to

the photograph shown below).

Nowad-

just the NO.1 piston's intake and exhaust valves.

MARK

ON

GEAR-~.

~

CASE

++-+++-+~-T-

63

25"

BlOC

INJECTION

PUMP

TIMING

MARK

TOP

DEAD

CENTER

ALIGNMENT

MARK

Westerbeke Diesel Engines

3.

Facing the front

of

the engine, rotate the crankshaft 170' clockwise

to

position the

No.2

piston at

TOC

of

its compression stroke. Now adjust the

No.2

piston's intake and exhaust valves.

NOTE: Adjust

all

valves

to

0.0098 inches (0.25 mm) with the engine cold.

ADJUST

VALVES

TO

8.8898

INCHES

[8.25

~MJ

Adjusting a valve's clearance with a feeler gauge.

Westerbeke

Diesel Engines

64

Injection

Pump

Timing

Adjustment

(Spill

Timing)

If your engine's fuel injection timing is not properly adjusted, the engine will not operate properly and will be difficult to start. Have the injection pump delivery rate checked

by

a well established fuel injection shop. Ad-

just the injection timing as follows:

NOTE: The fuel lever (throttle) must be in the

RUN

position while making the adjustment or

no fuel will flow to the fuel injection pump.

Refer

to

the illustration below when servicing the fuel injection pump. First remove the high-pressure fuel line from between the No.1 injector and the No.1 fuel delivery valve holder. Remove the No.1 fuel delivery valve holder and remove the delivery valve spring beneath the holder. Reinstall only the delivery valve holder and reattach the hight pressure fuel line

to

the delivery holder. Attach it so that the end that would connect

to

the fuel injector is pointing away from the engine.

Fuel

will flow from this line during the timing check.

DELIVERY

VALVE

HOLDE!

DELIVERY

VALVE

SPRING

DElI\lERY

VALVE

B A

II II

EL

....-"'-6"1t\

A,R

BLEED-IIIG

SCREW

PlDNHR

1i~~~2~LCQ"TROl

RAU

CONTROL

PUlIOM

PlUNGER

SPIII1I6

TAPPET

Cutaway View

of

the W 12B TWO's Fuel Injection Pump

Move the throttle lever to mits full open position and operate the electric lift pump. Rotate the crankshaft clockwise (as viewed from the front). catching the fuel

from the No.1 fuel line, until the instant the fuel com-

pletely stops flowing (no drips).

At

this instant, the 250 BTDC timing mark on the crankshaft pulley should be directly aligned with the timing indicator on

the front

of

the gear case (see the illustration

to

the

right).

65

MIIRK ON

GEIIR-_

INJECTION TIMING MIIRK

ON

PULLEY

CIISE

~~~~tV~~

Westerbeke Diesel Engines

If the specified injection timing

(250 BTDG)

cannot be attained, adjust the timing by increasing or decreas-

ing the thickness of the injection pump mounting shim. Changing the shim thickness

by

0.004 inch

(0.01

mm)

changes the injection timing

by

approximately one degree. To advance the timing, decrease the shim thick-

ness,

as

required. To retard the timing, increase the shim thickness, as required. Refer

to

your engine's

parts List for shim part numbers.

Westerbeke

Diesel

Engines

DELIVERY VALVE

HOLDER

INJECTION PUMP

ADJUSTING

SHIM

Fuel Injection Pump wtth

an

Adjusting Shim

66

LAY-UP

AND

RECOMMISSIONING

General

Many owners rely on their boatyards

to

prepare their craft, including engines and generators, for lay-up

during the off-season

or

for

long periods of inactivity. Others prefer

to

accomplish lay-up preparation them-

selves.

The procedures which

follow will allow you

to

perform

your

own lay-up and recommissioning,

or

to

use as

a check

list if others

do

the procedures.

These procedures should afford your engine protection during

a lay-up and also help familiarize you with

the maintenance needs of

your

engine.

If you have any questions regarding lay-up procedures, call

your

local servicing dealer; he will be more than

willing

to

provide assistance.

Propeller Coupling

The transmission and propeller half couplings should always be opened

up

and the bolts removed when-

ever the boat is hauled out of the water

or

moved from land

to

water, and during storage

in

a 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

System

A 50-50 solution

of

antifreeze and fresh water is recommended for use

in

the fresh water cooling system at

all times. This solution

may

require a higher concentration

01

antifreeze, depending on the area's winter

climate.

Check the solution

to

ensure that the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated

mixture. Operate the engine

to

ensure a complete circulation and mixture of the antifreeze con-

centration throughout the cooling system.

Now

recheck the antifreeze solution's strength.

Lubrication

System

With the engine warm, drain all the lubricating oil from the oil sump. Remove and replace the oil filter. (Place some paper towels and a plastic bag around the filter

to

catch the oil during its removal.)

When installing the new oil filter, be sure

to

apply a small amount of oil on the rubber sealing gasket at the

base

of

the lilter. Fill the sump with the correct amount of oil for

your

engine. (Refer

to

the"SYSTEM

SPECIFICATIONS"

section of this manual, page

8.)

Use an oil with an

API

specification of CC

or

CD.

Run

the engine and check

for

proper oil pressure and ensure that there are

no

leaks.

67

Westerbeke

Diesel

Engines

CAUTION

Do

not

leave the engine's old lubricating oil in the sump over the lay-up period. Lubricating

oil and combustion

deposITs combine

to

produce harmful chemicals which can reduce the

life

of

your

engine's internal parts.

Fuel

System

Top off

your

fuel tanks

WITh

No.2

diesel fuel. Fuel additives should be added at this time

to

control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary filter/water separator used in the system. Change the element in your primary fuel filter/water separator, if the fuel system contains one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and allow it

to

run for 5 -10 minutes

to

ensure that no air is left in the fuel system. Check for any leaks that

may

have been created in the fuel system during this servicing, correcting them as needed.

Sea

Water

Circuit

Close the thru-hull sea cock. Remove the sea water intake hose from the sea cock. Place the end of this hose into a

5-gallon bucket of clean fresh water. Before starting the engine, check the zinc anode found in

the primary heat exchanger on the engine and

clean

or

replace

IT

as required. Clean the sea strainer, if one

is installed in the inside of the

hull.

Start

the engine and allow the sea water pump

to

draw fresh water through the system. When the bucket

is empty, stop the engine and refill the bucket with an antifreeze solution

slightly stronger than needed for

winter freeze protection

In

your area.

Start the engine and allow all of this mixture

to

be drawn through the sea water system. Once the bucket

is empty, stop the engine. This antifreeze mixture should protect the sea water circuit from freezing during

the winter lay-up, as

well as providing corrosion protection.

Remove the impeller from your sea water pump (some antifreeze mixture will accompany

it,

so catch it

in

a

bucket). Examine the impeller. Acquire a replacement,

if needed, and a cover gasket. Do not replace the

impeller (into the pump) until recommissioning, but replace the cover and gasket.

Intake

Manifold

and

Through-Hull

Exhaust

Place a clean cloth, lightly soaked in lubricating oil, in the opening of the intake manifold

to

block the open-

ing. Do

not

shove the cloth out of sight. (If it is not visible at recommissioning, and an attempt is made

to

start the engine, you

may

need the assistance of a servicing dealer.) Make a note

to

remove the cloth prior

to

start-up. The through-hull exhaust part can be blocked

in

the same manner.

Starter

Motor

Lubrication and cleaning

of

the starter drive pinion is advisable, if access

to

the starter

permITs

ITS

easy

removal. Ensure that the battery connections are shut off before attempting

to

remove the starter. Take care

in

properly replaCing any electrical connections removed from the starter.

Westerbeke Diesel

Engines

68

Cylinder

Lubrication

It

is

not necessary

to

remove the fuel injectors from the cylinder head

to

squirt light lubricating oil into the

cylinders for the few months of normal lay-up. However,

if

you anticipate a longer lay-up period (12 months

or more), we recommended that this procedure be performed. The

light oil in the cylinders will prevent the

pistons rings from sticking

to

the cylinder walls. Ensure that you have replacements for the injector and

return

line sealing washers.

Spares

Lay-up time provides a good opportunity to inspect your Westerbeke engine to see

if

external items such

as drive belts

or

coolant hoses need replacement. Check your basic spares kit and order items not on hand,

or replace those items used during the lay-up, such

as

filters and zinc anodes.

Batteries

If batteries are

to

be left on board during the lay-up period, ensure that they are fully charged, and will remain

that way, to prevent them from freezing.

If there exists any doubt that 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 environment.

Recommissioning

The recommissioning

of

your Westerbeke engine after a seasonal lay-up generally follows the same proce-

dures as those presented

in

the "PREPARATIONS

FOR

STARTING" section, page

21,

regarding preparation

for starting and normal starts. However, some

of

the lay-up procedures will need

to

be counteracted before

starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold and from the through-hull exhaust port.

2.

Remove the sea water pump cover and gasket and discard the old gasket. Install the sea water pump impeller removed during lay-up (or a replacement, if required). Install the

sea

water pump cover with a

new cover gasket.

IWARNING~

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical

arcing or a

lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the

battery being serviced.

Shut off all electrical equipment

in

the Vicinity

to

prevent electrical ar-

cing during servicing.

3.

Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check to ensure that the batteries are

fully-

charged.

69

Westerbeke Diesel Engines

4.

Check

the

condITion of the zinc anode in the sea water circuit and clean

or

replace the anode as needed.

Note that

IT

is not necessary

to

flush the antifreeze/fresh water solution from the sea water coolant sys-

tem. When the engine is put

Into operation, the system will self-flush

in

a short period of time with no ad-

verse affects.

5.

Start the engine in accordance with procedures in the "PREPARATIONS

FOR

STARTING" section of this

manual, page

21.

Westerbeke

Diesel

Engines

70

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

Grade 4T

6mm

bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

Grade

6T

6mm

bolt head/nut

8mm

bolt head/nut

10mm

bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut

Grade

7T

8T

and 8,8

6mm

bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

Grade

5 capscrew

1/4

UNC

1/4 UNF 5/16 UNC 5/16 UNF 3/8 UNC 3/8 UNF

7/16 UNC

7/16 UNF

1/2 UNC

1/2 UNF

Pitch

1.25

1.5

1.25

(ISO)

1.5

1.75

1.5

2

1.5

2

1.25

1.5

1.25 (ISO)

1.5

1.75

1.25

1.5

1.25

(ISO)

1.5

1.75

1.5

2

1.5

2

71

Ib-lt

2.9 -

5.1

7.2 - 11.6

13.7 - 22.4

13.0 - 21.7

25.3

- 39.8

25.3

- 39.8

21.7

- 36.2

32.5

- 50.6

36.2 - 57.9

34.0 - 55.7

54.2

- 79.6

51.4

- 76.7

4.3 - 6.5

10.8 - 15.9

21.7-

32.5

19.5

- 30.4

36.2 - 57.9

36.2

- 50.6

34.7 - 49.2

5.8 - 8.7

14.5-21.7

28.9 - 39.8

26.8 - 37.6

54.2 - 75.9

50.6 -

65.1

43.4 - 61.5

57.9 - 86.8

72.3

-108.5

68.7 -101.3

108.5

- 166.4

101.3 -159.1

9 -

11

-

13

18 -

20 21 -23 28 - 33

30 -

35 44

- 49

50

- 55

68 -

73 73

- 80

kg-m

0.4-0.7

1.0

- 1.6

1.9 -

3.1

1.8 - 3.0

3.5 - 5.5

3.5

- 5.5

3.0 - 5.0

4.5 - 7.0

5.0 - 8.0

4.7-

7.7

7.5-11.0

7.1

-10.6

0.6 - 0.9

1.5 - 2.2

3.0 - 4.5

2.7

- 4.2

5.0 - 8.0

5.0 - 7.0

4.8 - 6.8

0.8 - 1.2

2.0 - 3.0

4.0 -

5.5

3.7 - 5.2

7.5-10.5

7.0 - 9.0

6.0 -

8.5

8.0

-12.0

10.0 -15.0

9.5

-14.0

15.0 - 23.0

14.0 - 22.0

1.2 - 1.5

1.5-

1.8

2.5

- 2.8

2.9

- 3.2

3.7-4.6

4.1

- 4.8

6.1

- 6.8

6.9

- 7.6

9.4-10.1

10.1-11.1

Westerbeke Diesel EnginE

TORQUE SPECIFICATIONS

Cylinder head bolt

(Ma)

* 25.3 - 28.9

3.5 -

4.0

(See

the"

Tightening

Cylinder

Head

Bolts"

section of this manual on page 63.)

Rocker cover nut

(Ma)

3.6 -

5.1

0.5 - 0.7

Connecting rod cap nut 23.1 - 25.3 3.2 - 3.5

Flywheel bolt 47.0 - 50.6 6.5 - 7.0

Crankshaft pulley nut (M24) 108.5

-144.7

15 - 20

Oil drain plug 36.2 - 43.4

5.0 - 6.0

Oil filter

7.9 - 9.4

1.1

- 1.3

(or tighten firmly

by

hand)

Nozzle holder

36.2 - 43.4 5.0 - 6.0

Nozzle holder and retaining nut 43.4 - 57.9 6.0 -

B.O

Glow plug 10.8 - 14.5

1.5 -

2.0

Starter B terminal nut (on

copper

stud) 7.2 - 8.7

1.0 - 1.2

* NOTE:

MB

indicates Metric, 8

mm

thread diameter

Westerbeke

Diesel

Engines

72

SPARE PARTS

Since

a possibility exists in which the engine

may

need

to

be

serviced at sea

or

while in a port other than

your

home

port, certain spare parts should be kept on board

to

help minimize delays in

your

voyage. Please

refer

to

your

engine's Parts List for part numbers when ordering spare parts.

Listed

below are those spare parts that should be carried on board at all times.

1

. An I mpeller Kit

2.

A Fuel System hardware Kit

3.

An Electric Fuel Lift

Pump

Filter and a Secondary Fuel Filter.

4.

An Alternator/Sea Water Pump Belt

5.

Hose Clamps

6. A Spare Oil Filter with a Spare Quart of Diesel Service Engine Oil along with a Quart of Transmission Lubricant and a

Gallon of Premixed Antifreeze.

Other parts, whose life expectancy cannot be accurately predetermined, should

be

carried on board (in ad-

dition

to

those listed above) especially if the vessel is

to

be taken on

long

ocean voyages. These parts are

listed below.

1.

Fuel Injectors

2.

Glow

Plugs

3.

Cooling System Hoses

4.

An Alternator

5.

A Starter

6.

A 20

Amp

DC Circuit Breaker

7.

An Electric Fuel Lift

Pump

8.

A Sea Water

Pump

9.

Battery Terminal Connectors

The spare parts

listed directly above are those

we

recommend be carried on board during long ocean

voyages.

You

may

wish

to

ask other boat owners

who

have similar crafts and

who

have completed long

ocean voyages as

to

what spare parts they carried on board and what parts were needed at specific times

of the voyage. From the

list provided directly above and from these inquiries,

you

can determine what spare

parts

may

be needed. In addition, ~ you are planning a long ocean voyage, consult

your

local Westerbeke

dealer for

a listing of the Westerbeke dealers located on

your

route.

73

Westerbeke

Diesel

Engines

iNDEX

A

Adjustment, Injection Pump Timing

....

,..,. .....

,..

,.,.,.,.,.,.,.,. ,.,.,.,.,.,.,.,.,.. ,.,.65

ADJUSTMENTS,

MAINTENANCE AND ,.,.,.,.,.,.,.,.,.,.,.,.,.

....

,.,.,.,.. .

..

,.60

Adjustment, Valve Clearance ,..,.,.,.

..

,.,.,.,.,.,.,.

..

,.,.,.",.,.,.,.. ,.,.,.,.,..,.

.......

,.,.,.,..,.

..

,.,..,..,.. ,..,.,.,..63

Admirals Panel.,..,.

..

,.,..,..,.

..

,.,..,.,.,.,..,..,.,..,..,.,.,..,..,.

..

,..,... ,.,. ......

,.

...

,..,.,.,..,..,.

....

,. ,.

.....

,.

.... 24

ADMIRALS PANEL, DC WIRING DIAGRAM # 36844,.,.,..,..,..,.,.,.,.,.,.,..,.,.,..,.,.,.,..,.

..

,.,.,.,.,..,.,..,.,. 36 and 37

Alignment (BW 3 Transmission)

,.,..,.,.

..

,.,.,.,..,.

..

,..,..,.

..

,.,.

..

,.,.,.,..,..,..,.

..

,.,.,.,..,..,. ..... ,.,. .... ,..,..,..,.

...

,..,..,..,.,..55

Alignment

(HBW

50

Transmission) .,.,.,.,.,.,.,.,..,.,.,.,..,..,.,.,.,.,.,..,.

..

,..,.,.

...

,.",.

..

,..,..,..,..".,..,..,..,.,..,..,.,.

..

,..,..51

Alternator ...................................................................................................................................................... 33

Alternator and Water Pump Drive Belt

Tension,.,.,..,..,..,.,.,.,.,.,..,..,..,..,..,..,.,.,.,.,.,.,.,.,.,..,..,..,..,.,..,..,..,..,.,..42

Alignment

of

the Engine (Installation Checks). ,.,.,.,.,. ,..,.,.,..,.. ,.,.,..,. ,.,.,..,..,..,..,.. ,.,.,.,..,.. ,.,.,.,. ,.,.,.,. ,.,.,.,..,.

.13

ANTIFREEZE CONCENTRATION DATA ..........................

,.

..................................

,.

.................................... .40

Automatic Alarm System (Installation Checks) ,.,.,.,.,.,.,.,. ,.,.,.,.,.,.,.,.,.,.,.. ,.,.. ,.,.,.. ,.,.,.,.. ,.,.,.,..,.,.. ,.,.,. ,.,.,.. ,..18

B

Back-Pressure, Exhaust (Installation Checks) ..........

,.

................................................................................ 16

Batteries (Lay-up and Recommissioning) ................................................................................................... 69

Battery Specification ..........

,.

........................................................................

,.

........................................... ,..33

Belt Tension, Alternator and Water Pump Drive,.,.",.,.,.,.,.,.,.,.",.,.,.,.,.

..

,..,.,.,.,.,.,.,..,.,.,.,.,.,.,..,.,..,.,.,.,.,.,.,..42

Bolts, Engine (Installation Checks) ,.,.,.,.,.,.,. ,.,.,.,.,.",.,.

..

,.,.. ,.,.,.

..

,.,.,..,.

...

,.,.. ,.,.,.,..,.,. ,.".,..,.. ,.,.,.,.

..

,.,.,..,.

..

,.12

Bolts, Torquing Cylinder Head ,.,.,.. ,..,.,.,. ,..,.,. ,.,.,. ,.,.,..,..,.. ,.,.,..,.. ,.,.,. ,.,.,.. ,.,.,.,.. ,.,.,..,. ,.,.,.,.,.. ,.,.,.,..,..,..,.,.,.

.63

Break-in Procedures, Engine ...................................................................................................................... 28

BW 3

TRANSMiSSiON ................

,.

....................................

,.

......................................................................... 54

c

Captains Panel ...........................................

,.

...............................................................................................

.23

CAPTAINS PANEL, DC WIRING DIAGRAM # 38467,.,.

...

,..,.,.

..

,..,.,.,.,..,.,.

..

,.

..

,.,.,.,.

..

,.,.,.,.,.,.

..

,.,.,. 34 and 35

Change, Engine

Oil (to include filter) ,.,..,.,.,..,.,.,.,.,.,.,.,.,..,.,.,.

..

,.,..,..,..,.,.,..,.

..

,.,.,.,..,..,.,..,..,..,.,.,.,..,.,..,.,.

...

.48

Charging Voltage Test ................................................................................................................................. 38

CHECKS, INSTALLATION ,.,. ....

,..

,.

..

,.,.,.,.,.,.,. ,.,.,.,.,. ,.,.,.,..,.,. ,.,.,.

...

,.,.,. .... ,..,..,..,.,.,..,..,.,..,.. ,.,.,.,..,..,..

,.

...

,..,.1 0

CirCUIT,

Fresh Water ....

,.

............................................................................................................................... 39

Circuit,

Sea Water .................................

'"

...................................................................................................

.42

Circutt, Sea Water (Lay-up and Recommissioning) ,..,.,.,..,.,.,.,..,.,.

..

,.,.,..,.,.,.,.,.,..,.,.,.,.,.,..,.,.,.,.,.,.,.,.,.,.,.,..68

Clearance Adjustment, Valve ...................................................................................................................... 63

Cold Conditions, Starting Under

,.,.,.,.

,.

..

,.,.,.

...

,.,.,..,.. ,.,.,.,.,.,..,.. ,.,.,..,.. ,.,.,.,..,.

..

,.

....

,..

,.,.

..

,..,..

,.

...

,..,..,..,.

..

,.

,.29

CONCENTRATION

DATA,

ANTIFREEZE .................................................................................................... 40

Conditions, Starting Under Cold

...

,..

,..,..,.,.,.,..,.,. ,.",..,..,.. ,.,.,.. ".,.

..

,.,..,.,.,..,..,..,.,.,.. ,.,..,..,..,..,..,.. ".,.

..

,.,.,.

...

29

Conditions, Starting Under

Normal.,..,..,.

..

,.,..,.. ,.,.",.,.. ,..,.

..

,..,..,..,..,..,.. ,.,.,.,.

..

,.,.,..,..,.,..,.

..

,.,..,..,..,..,..,.,.,. ,.29

Connecting Pressure Sensing Devices

to

Oil Galleries (Installation Checks),.,.,..,..,..,.,.

...

,.

..

,.,.,.,.,.,.,..,.,.18

Controls (BW 3 Transmission)

,..

,.,.,.,. ,.,.,.,.,.,..,.,.,.. ,.,.,.,.,.,.. ,.,.,..,..,..,..,.,. ,.,.,.,.. ,.,.,..,..,. ,.,.,.,..,..,..,.. ,.,.,.,..,.

..

55

Controls (HBW 50 Transmission),..,..,.,.,.. ,.,.,.,.. ,.,.,.,.,.,.,.,..,..,..,.,. ,.,.,.,..,.,. ,.,.,.,.,.,..,..,.,.. ,.,.,.,..,..,..,.. ,.,.,..,. ,.52

Cooling System (Installation Checks) ,.,.,.,. ,.,.,. ,.,.,..,.. ,.,.,.,.

..

,..,.,.,. ,..,.,.,..,.

..

,..,.. ,.,.,..,. ".,..,..,..,.. ,..,.. ,.,.,.,.. ,..18

COOLING SYSTEM

.....

,.

.............................................................................................................................. 39

Cooling

System, Fresh Water (Lay-up and Recommissioning),.,.,.,.,.,..,.,.,.,.,.,.,.,..,..,.,..,..,..,.,.,..,.,.,.,..,..,.67

Control Circuit, Engine 12-Volt DC,.,.,.,.,.,.

...

,..

,.,.,.,.,.,.

..

,.,.. ,.,.,.,.,.,.,.,.. ,.,.,.

..

,.,.,.,.,.,..,.,..,..,.,.,..,..,.

...

,.,.,..,.. ,.33

Coupling, Propeller (Installation Checks) ,.,.,.,..,..,.,.,..,..,..,.,.,..,..,.,..,.,.,.,..,..,..,.,.,.,.,.,..,.

..

,.

..

,.,.,.

..

,..,.,.

...

,.,..13

Coupling, Propeller (Lay-up and Recommissioning) ,.,.,..,..,..".,..,.,.,.,.,..,..,..,.,.,.,.,..,.,..,..,.,.,.,..,..,..,..,.,.,.

..

67

Cylinder Head Bolts, Torquing

.................................................................................................................... 63

Westerbeke Diesel Engines

74

Cylinder Lubrication (Lay-up and Recommissioning) ...............................................................................

69

CAUTIONS

ENGINE

NOT

SHIPPED WITH

OIL

........................................................................................ 10

LIFTING SLINGS ...................................................................................................................

11

SCOOP-TYPE

HULL

FITTINGS ............................................................................................. 18

PROLONGED CRANKING INTERVALS ................................................................................. 26

ENGINE SHUTDOWN ............................................................................................................ 28

PROLONGED CRANKING INTERVALS .................................................................................

31

DAMAGE

TO BATTERY

CiRCUiT

.......................................................................................... 33

QUICK-CHARGING BATTERY ............................................................................................... 33

ALTERNATOR

TESTING ....................................................................................................... 33

EXCESSIVE

BELT

TENSION ................................................................................................. 42

TRANSMISSION GEAR COVER ............................................................................................ 53

TRANSMISSION GEAR COVER ............................................................................................

56

D

DC Control

CirCUIT.

Engine 12-Volt .............................................................................................................

33

DC WIRING DIAGRAM # 36844 (ADMIRALS PANEL) .................................................................. 36 and 37

DC

WIRING DIAGRAM # 36467 (CAPTAINS PANEL) ................................................................... 34 and 35

DESCRIPTION OF INSTRUMENT PANELS ............................................................................................... 23

Description

of

Starting System ...................................................................................................................

22

Devices

to

oil Galleries. Connecting Pressure Sensing (Installation Checks) .......................................... 18

Diesel Engine. Understanding the ................................................................................................................ 4

Diesel Fuel ...................................................................................................................................................

30

DISCLAIMER. PRODUCT SOFTWARE.

........................................................................................................ 1

Domestic

Hot

Water .................................................................................................................................... 45

Drain.

Oil (Installation Checks) ................................................................................................................... 17

E

Electrical System (Installation Checks) ...................................................................................................... 19

ELECTRICAL

SySTEM ................................................................................................................................ 33

Elements. Replacing the Fuel Filter ............................................................................................................

31

Engine 12-Volt DC Control Circuit .............................................................................................................. 33

Engine.

Alignment of the (Installation Checks) .......................................................................................... 13

Engine. Break-in Procedures ...................................................................................................................... 28

Engine Bolts (Installation Checks) .............................................................................................................. 12

Engine. Diesel. Understanding the ............................................................................................................... 4

Engine. Foundation

forthe

(Installation Checks) ...................................................................................... 12

Engine

Oil .................................................................................................................................................... 47

Engine

Oil Change (to include filter) .......................................................................................................... 48

ENGINE TROUBLESHOOTING .................................................................................................................. 57

Equipment. Inspection of .............................................................................................................................. 2

Exhaust Back-Pressure (Installation Checks) ............................................................................................ 16

Exhaust.

Intake Manifold and Through-Hull (Lay-up and Recommissioning) .......................................... 68

Exhaust

System (Installation Checks) ........................................................................................................

15

Exhaust System Failures (Installation Checks) .......................................................................................... 17

75

Westerbeke

Diesel

Engines

F

Failures, Exhaust System (Installation Checks) .........................................................................................

17

Filters, Fuel ...................................................................................................................................................

30

FORWARD ...................................................................................................................................................... 2

Foundation for the Engine ...........................................................................................................................

12

Fresh Water Circuit ......................................................................................................................................

39

Fresh Water Cooling System (Lay-up and Recommissioning) ..................................................................

67

Fuel, Diesel ...................................................................................................................................................

30

Fuel Filters ....................................................................................................................................................

30

Fuel Filter Elements, Replacing the .............................................................................................................

31

Fuel Injection Pump .....................................................................................................................................

32

Fuel System (Installation Checks) ...............................................................................................................

19

Fuel System (Lay-up and Recommissioning) .............................................................................................

68

FUEL SYSTEM .............................................................................................................................................

30

Fuel System, Priming the .............................................................................................................................

31

G

Galleries, Connecting Pressure Sensing Devices

to

Oil (Installation Checks) .......................................... 18

GENERAL ....................................................................................................................................................... 4

GENERAL SPECiFiCATIONS ........................................................................................................................ 7

H

HARDWARE TIGHTENING TORQUES, TABLE OF STANDARD ...............................................................

71

HBW

50

TRANSMISSION ............................................................................................................................

50

Head Bolts, Torquing Cylinder ....................................................................................................................

63

Hot Water, Domestic .................................................................................................................................. .45

INDEX ...........................................................................................................................................................

74

Injection Pump, Fuel .................................................................................................................................... 32

Injection Pump Timing Adjustment ............................................................................................................. 65

I nspection of Equipment ............................................................................

'"

................................................ 2

INSTALLATION CHECKS ............................................................................................................................ 10

I~STRUMENT

PANELS, DESCRIPTION OF ............................................................................................... 23

Intake Manifold and Through-Hull Exhaust (Lay-up and Recommissioning) ............................................

68

Intake System, Sea Water (Installation Checks) ......................................................................................... 19

L

LAY-UP AND RECOMMiSSiONING ............................................................................................................

67

Lifting, Rigging and (Installation Checks) ..................................................................................................

11

Location (Installation Checks) ..................................................................................................................... 10

Lubrication (BW 3 Transmission) ................................................................................................................

54

Lubrication, Cylinder (Lay-up and Recommissioning) ...............................................................................

69

Lubrication (HBW 50 Transmission) ........................................................................................................... 50

Lubrication System (Lay-up and Recommissioning) ................................................................................. 67

Westerbeke

Diesel

Engines

76

LUBRICATION SYSTEM .........................................................................................................................

47

M

MAINTENANCE AND ADJUSTMENTS .......................................................................... . . ... 60

Manifold, Intake and Through-Hull Exhaust (Lay-up and Recommissioning) ...... ............... . ........

68

Motor, Starter (Lay-up and Recommissioning)

.... .... .... ....

...

....

..

....

.......

...

.... ....

....

..

............... ............ .

...

68

N

Normal Conditions, Starting Under ........................................................................................................... 29

o

Oil Change, Engine (to include filter) .................................................................................................

.48

Oil Drain (Installation Checks) ................................................... ..................................... .

...

17

Oil, Engine .................................................................................. ..................................................... .

.....

47

Oil Galleries, Connecting Pressure Sensing Devices

to

(Installation Checks) ......................... .

18

Oil Pressure ................................................................................................................................................

47

Operation, Sailing (BW 3 Transmission) ................................... ........................ ........................ . .........

56

Operation, Sailing (HBW

50

Transmission)..................................................................................... . .....

53

Ordering Parts ............................................................................................................................................. 4

p

Panel, Admirals ........................................................................................................................................... 24

Panel, Captains ..........................................................................................................................

'"

..............

23

PANELS, DESCRIPTION OF INSTRUMENT .............................................. _ ..............................................

23

Parts, Ordering .............................................................................................................................................. 4

Parts, Spare ............................................................................................. " ..................................................

73 PREPARATION

FOR

STARTING ............................... ................................ ............................ .

...

21

Pressure, Oil ..............................................................................................................................................

47 Pressure Sensing Devices

to

Oil Galleries, Connecting (Installation Checks) ..................... . ..... 18

Priming the Fuel System. .......

.... .... ....

.....

..... .......

.... ....

....... ..........

...

....

...

.... ....

.......

..

. .........

...

....

. ....

31

PROCEDURE, STARTING ........................................................................................................................

26

PROCEDURE, STOPPING .........................................................................................................................

28

Procedures, Engine, Break-in ................................................................................................. .

PRODUCT SOFTWARE DISCLAIMER. ........................................................................................ .

Propeller (Installation Checks) .................................................................................................... .

Propeller Coupling (Installation Checks) ...............................................................................

..

Propeller Coupling (Lay-up and Recommissioning) ........................................................ .

.

...

28

..

1

.

...

13

.

..

13

.

...

67

Propeller Size, Recommended (BW 3 Transmission)....................... . . ............ .

..

.............

56

Propeller Size, Recommended (HBW

50

Transmission) ............................................ .

Pump, Fuel Injection ......................................................................................................... .

Pump, Injection, Timing Adjustment .............................................................................. .

Pump, Sea Water

....

...... .......... ........ ....... ......

....

...

....

...

.... ....

......... .......... .... . ........................ .

. ..... 53

.....

32

. ............... 65

.... 42

77

Westerbeke Diesel Engines

R

Recommended Propeller Size (BW 3 Transmission) ................................................................................ 56

Recommended Propeller Size (HBW 50 Transmission) ............................................................................ 53

Recommissioning (Lay-up and Recommissioning) ................................................................................... 69

Replacing the Fuel Filter Elements ..............................................................................................................

31

Rigging and Lifting (Installation Checks) ....................................................................................................

11

S

Sailing Operation (BW 3 Transmission) ...................................................................................................... 56

Sailing Operation (HBW 50 Transmission) ................................................................................................. 53

Sea

Water Circuit ........................................................................................................................................ .42

Sea

Water Circuit (Lay-up and Recommissioning) ....................................................................................

68

Sea

Water Intake System (Installation Checks) .......................................................................................... 1 9

Sea

Water Pump .......................................................................................................................................... 42

Sensing Devices

to

Oil

Galleries, Connecting Pressure (Installation Checks) .......................................... 18

Service (BW 3 Transmission) ...................................................................................................................... 56

Service (HBW 50 Transmission) .................................................................................................................. 53

Shifting (BW 3 Transmission) ......................................................................................................................

56

Shifting (HBW 50 Transmission) ................................................................................................................. 52

SOFTWARE DISCLAIMER, PRODUCT ......................................................................................................... 1

Spare Parts ................................................................................................................................................... 73

Spares (Lay-up and Recommissioning) ..................................................................................................... 69

Specification, Battery ...................................................................................................................................

33

SPECIFICATIONS, GENERAL ....................................................................................................................... 7

Starter Motor (Lay-up and Recommissioning) ...........................................................................................

68

STANDARD HARDWARE TIGHTENING TORQUES ..................................................................................

71

STARTING, PREPARATION

FOR

................................................................................................................

21

STARTING PROCEDURE ............................................................................................................................ 26

Starting System, Description of ................................................................................................................... 22

Starting Under Cold Conditions ..................................................................................................................

29

Starting Under Normal Conditions .............................................................................................................. 29

STOPPING PROCEDURE ........................................................................................................................... 28

SYSTEM(S),

Automatic Alarm

(Installation Checks) .............................................................................................

18

Cooling (Installation Checks) ............................................................................................................ 18

COOLING ...........................................................................................................................................

39

Electrical (Installation Checks) ..........................................................................................................

19

ELECTRiCAL ...................................................................................................................................... 33

Exhaust (Installation Checks) ............................................................................................................ 15

Exhaust, Failures (Installation Checks) ............................................................................................. 17

Fuel (Installation Checks) ............................................

..

................................................................ 19

Fuel (Lay-up and Recommissioning) ................................................................................................

68

FUEL.............................................................................................................~

Intake, Sea Water (Installation Checks) ............................................................................................

19

Lubrication (Lay-up and Recommissioning) .................................................................................... 67

LUBRICATION ................................................................................................................................... 47

Priming the Fuel .................................................................................................................................

31

SPECiFiCATIONS ................................................................................................................................ 8

Westerbeke

Diesel

Engines

78

T

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES .............................................................

71

Tension, Alternator and Water Pump Drive Belt ...... ....... ...........

... ...

....

.........

...

..........

...

......

... ...

....

.

..

42

Test, Charging Voltage ................................................................................................................... .

...

38

THE BW 3 TRANSMiSSiON...........................................................................................................

.54

THE HBW 50 TRANSMISSION .............................................................................................................

50

Thermostat

..

... ... ... ... ... ...

......

.... .... .... .... ....

...

....

......... .......... .......

...

....

...

......

...

.....

....

...

....

......

... ...

.... . ..

41

Through-Hull Exhaust, Intake Manifold (Lay-up and Recommissioning) ...................................... .

...

68

Timing Adjustment, Injection Pump ..........................................................................................................

65

Torquing Cylinder Head Bolts ................................................................... _ ...............................................

63

TROUBLESHOOTING, ENGINE............................................. .......................... .

...............

57

U

Under Cold Conditions, Starting ...............................................................................................................

29

Under Normal Conditions, Starting ..........................................................................................................

29

Understanding the Diesel Engine ................................................................................................................. 4

v

Valve Clearance Adjustment .....................................................................................................................

63

Ventilation (Installation Checks) ............................................ _ ..................................................................

20

Voltage Test, Charging ............................................................................................................................... 38

W

Water Circuit, Fresh ................................................................................................................................... 39

Water Circuit,

Sea ......................................................................................................................................

42

Water Circuit, Sea (Lay-up and Recommissioning) ............................ _ ..................................................... 68

Water

Cooling System, Fresh (Lay-up and Recommissioning) ............................................................... 67

Water, Domestic Hot ...................................................................................................................................

45

Water, Pump, Sea ............................................. _ .........................................................................................

42

WIRING DIAGRAM # 36844,

DC

(ADMIRALS PANEL) ................................................................. 36 and 37

WIRING DIAGRAM

# 36467,

DC

(CAPTAINS PANEL) ..................................................................

34

and 35

IWARNINGS~

DIESEL EXHAUST GASES ...................•••....•..•...........•...•..••...••.............................................

17

FLAMES NEAR DIESEL FUEL ...............••••.••••.•.•..•................................................................ 20

SERVICING BATTERIES .....•............•....•••••••••••..................................................................... 20

ADJUSTING

DRIVE BELT TENSION .......•••••.••••.................................................................... 42

SERVICING BATTERIES ....................................................................................................... 69

79

Weslerbeke Diesel Engines

YOUR NOTES

Westerbeke 12B TWO Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual