Westerbeke 12C- TWO, 12D-TWO Operator's Manual

OPERATORS

MANUAL'

MARINE

12C~TWO

D'IESEL

a

PUBLICATION NO.039717

REVISION

JANUARY

ENGINES·

120-TWO,

3

2011

..

~

WESTERBEKE

,

MyLES

,

W.B,SITE:

.

L;r

CORPORA

STANDISH

WWW.WESTERBEKE.COM

Member

TlON • 150

INDUSTRIAL

National

Marine

PARK'

JOHN

HANCOCK

TAUNTON

Manu/acturers

ROAD

MA

.

Association

02780

A

WARNING

..

Exhaust colorless unconsciousness

exposure

-Dizziness

-Nausea

-Headache

IF.

GET seek

until

gasses

Weakness

YOU

ORANYONE

OUT

medical it

has

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gas. can

Include:

and

INTO

belln

contain

Carbon

tHE

attention.

N·

Monoxide

and

death.

Sleepiness

ELSE

FRESH

inspected

I

N G

Carbon

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON liviltg/sleeping

They obtainable

ANY

the

repaired.

near

MONOXIDE

are

inexpensive

an

odorless

and

of

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

unit

and

DECAL

and

should

your

also

quarters

at

your

anil

can

cause

Monoxide

Coherently

SYMPTOMS,

symptoms

do

is

provided

engine

recommends

DETECTORS

and

local

not

restart

be

fixed

or

of

your

easily

marine

persist,

by

generator.

installing in vessel.

store.

to

the

a

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

65

WARNING

gasoline

of

its

constituents

State

of

California

birth

defects,

engine

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

to

folww fundamental precautions. take

the

personne~

The

follOWing

the

American

PREVENT

A

while

powel.

•

Do enclosures

•

Shut equipment

•

Use equipment.

•

Make (particularly

•

Remove electrical

•

Do circuits, transfer result

• Electrical shock capacitor.

together.

PREVENT

. A

exhaust

very

•

Always recovery

A

•

In before

Know

when

necessary

and your

precautions

machinery.

safety instructions

Boat

and

Yacht

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not

operate

and

off electrical

insulated

sure your

wristwatch

equipment.

not

connect ntility shore power

except

switch.

if

this

procedure

Discharge

SHOCK

Do

not

lunning,

is

this

machinery

covers

power

mats

whenever

clothing

shoes)

when

and all jewelry

through

Damage to vessels

results

BURNS -HOT

WARNING:

system

hot!

check the

WARNING:

case of

touching

Do

not

components.

engine

tank.

Steam

an

engine

the

carefully.

Most

accidents

rules

dangerous

touch

01

plesent

in place.

before

and skin

a ship-to-shore

is

from handliog a cbarged

capacitor

to

protect

are

Council

AC

electrical

when

connected

at

without

accessing

working

handling

not

followed.

by

conditions

yourself,

in

compliance

(ABYC)

these

connections!

electrical

on

are

dry,

electrical

when

to

vessels

double

AC

generator

shorting

ENGINE

touch

hot

engine

A

coolant

can

overheat,

engine

lunning

cause

allow

or

checking

level

injury

the

engine

at

the coolant.

are

and

exist and

your

with

standards.

connections

to

shore

electrical

not

damp

equipment.

working

terminals

parts

on

AC

throw

may

01

gets

the coolant

01

death!

engine

to

cool

PREVENT

A

• Prevent sparks punlp, vapors. removing

• Do arrester.

•

Do Backfire

•

PREVENT

A

in

jUlY

•

BURNS -FIRE

WARNING:

to

or other

Use a suitable

not

operate

not

operate

Do

not

smoke

the

fuel engine/generator clean and chances

Be

aW\ll'e

File

can

cause

flash

fires.

Do

not

smoke

occur near the

poten!ial

the

fuel

without a Coast

Backfue

with

can

cause sevete

or

system t(eep the compartment

of

fire.

Wipe

- diesel

container

line,

can

cause

the

pennit

up

fueLw.jj]

carburetor,

sources

carburetor,

severe

air

cleaner/silencer removed.

injury

flames

free

all

spilled fuel

burn.

BURNS -EXPLOSION

WARNING:

01

death!

Follow hatches

after

fueling. running before starting

All

fuel

when

handling well-ventilated equipment

Do

not

Shut

off

the

fuel

spill.

DO

sources

servicing. the

fuel

Do

not

Be

sure

Be

certall\

free ofleaks. .

Make

sure a fire properly Extinguishers rated

for

all

Explosions

re-fueling

closed

the

vapors

fill

the system.

NOT

of

Ensure proper ventilation

system.

alter

all

maintained.

applications encountered

safety

when

Check below

blower.

your

are

highly

and

area

and out of

the fuel

fuel

service

Take

allow

fire

near

or

modify

fuel supplieiiiave a

fuel line

extinguisher is Installed

flom

instructions.

fueling.

Run

engine.

storing

away

tank(s)

the

fittings

ABC

Open

for

the

blower for

explosive.

fuels.

from

the

reach

while

valve care in catching any

smoking,

fuel

system

the

fuel

are

Be

familiar with

by

the

injury

01

death!"

or

permit

flaines

or

fuel line,

of spilled fuel

to

catch all fuel when

or fuel

Guard

injury or death.

or

death.

or

sparks

of debris to minimize the

fuel

and ventilate cabin

fumes/vapor before

Use

Store spark-producing of children.

the engine

at

the

engine open

or

exists

system.

positivei~i\Utoff

adequately tightened

NFPA

in

this

filter,

filters.

Approved

to

occur near

and

the

and

engine oil.

vapors

can

Keep

the vessels

four

minutes

extreme

fuel

in a

is

when

any

fuel

flames,

engine

when

nearby

its

proper

are

appropriate

environment.

fuel

or

fuel

flame

cause

care

running.

servicing

that might

or other

servicing

valve.

and

is

use.

~

WESTERBEKE

Engines & Generators

•

I

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect generator. it

last.

•

Make

certain

starting.

•

Make

certain

installed

BATTERY

A

or

death!

•

Do being highly

arcing equipment

ing

. •

Never tive not

together.

Ventilate accumulation disturb is

•

Avoid burns wristwatch, the

•

Always the and

BATTERY

A

severe

•

When

level,

tion.

If

with inadvertently

before starting

EXPLOSION

WARNING:

not

smoke or

serviced.

explosive

or

by

servicing.

connect

(+)

connection

test the battery condition

Sparks could

any

the

being

charged.

contacting

or

sparks that

battery.

tum the

battery

reconnect it last whenservicing

ACID

WARNING:

injury

servicing

wear rubber

Batteries contain sulfuric acid

it

comes

water.

STARTING

Accidental

the

battery

Remove

all

personnel

all

covers,

Battery

allow

Lead

gas,

lit

tobacco

in

the

vicinity

the

negative

compartment containing batteries

of explosive

battery

charger

the

rings,

and

battery

connections.

Sulfuric

or

death!

the

in contact

Acid

may

when

starting

cables

the

negative

are

guards,

the

engine.

explosion

an

open

acid

batteries emit

which

products.

to

prevent

terminal

ignite

gases.

connections

terminals

could

cause

any

other jewelry

charger off before disconnecting Remove

acid

battery

gloves,

a rubber

with

your

splash

removing electrolyte

can

before servicing

lead

first

clear of

and

hatches

can

flame

can

be

ignited

Shut off all electrical

electrical

(-) battery

of

the

starter

by

shorting

battery

gases

To

avoid

with

tools,

an

explosion.

the

negative

the

in

batteries

or

checking

apron,

which

skin,

on the

skin

cause

and

the

engine

are

cause

near

the

hydrogen,

by

cable

solenoid.

the

or sparks,

while

etc.,

before

battery.

can

the

electrolyte and is

wash

it off

or

into

caps.

injury

the

engine/

reconnect

before

re-

injury

battery

a

electrical

arcing dur-

to

the

posi-

Do

terminals

fuel

vapors.

to

prevent

do

not

the

battery

to

prevent

Remove

handling

lead

first

cause

eye

protec-

destructJve.

at

once

the

eyes

TOXIC

•

• Be

• Don't

• For additional information refer to

EXHAUST

A

WARNING:

Ensure

that discharged regularly water-injected

sure

the

Run

blowers

run equipped detector that builder

or

(educational information

A

WARNING:

odorless nausea

•

• Although diesel engine exhaust

AVOID

A

or

•

gas.

or

Do

not

use

fumes

can

Exhaust sulfur

resulting

Do

not

install exhaust outlet through exhaust enter

the

flow

of

exhaust gas

is

present in diesel exhaust

symptoms

poisoning

Vomiting

Dizziness

Headache

Nausea

MOVING

WARNING:

death!

Do

not service

arises

in

ing

adjustments,

ing parts

GASES

Carbon

monoxide

the

exhaust system

from

the

engine.

for

leaks

and

elbow

unit

and

when

running the

the

generator set

with

a functioning

complies

dealer for installation of approved detectors.

Carbon

Inhalation

Check

make

sure

is

securely

its

surroundings

or

marine

with

ABYCA-24.

on

Carbon

monoxide

produces

death!

copper

tubing

in

diesel

rapidly

destroy

copper

causes

rapid deterioration

in exhaust/water leakage.

where portholes, discharge

exhaust

exhaust.

fumes

are:

or

vents,

or

aii'

outlet

is

near

discharge

Avoid

from

signs

outlet

overloading the craft.

gasoline engines, carbon

of carbon

Inability to think coherently Throbbing in temples Muscular twitching Weakness

PARTS

Rotating

the

which

it

and

hot exhaust system

parts

engine

while

is

absolutely necessary to

use

extreme

is

generator

engine

conditioners.

fume~.

monOXIde

can

care

(CO)

is a deadly

adequate the

attached.

(CO)

flu-like

exhaust

tubing

the

and

gases

it is

components.

to expel gases

the

exhaust system

exhaust

are

well ventilated.

set or

unless

carbon

monoxide

Consult your boat

ABYC

T-22

Monoxide).

is

an symptr1ms,

systems.

in

exhaust

of

exhaust

waterline, water

close

or

are

not

S?me

Inhalation or

and

sleepiness

cause

injury

running.

to

avoid

gas!

manifold!

engine.

the boat is

invisible

Diesel

systems.

copper tubing

can

be

drawn

If

the

engine

could

restrict

the

as

toxic

as

monoxide

o~

the

If

a situation

make

operat-

touching

mov-

~

WESTERBEKE

Engines & Generators

ii

SAFETY

INSTRUCTIONS

OPERATORS

Many of

in

your

notes

to

carefully,

procedures.

GASOLINE

Preparations begin

with

Yacht

Council's

a

combination Sections of H-2

Ventilation

H-24

Gasoline

P-l

Exhaust

P-4

Inboard

DC

E-9

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

install a

a thorough

of

the

ABYC

Fuel

Systems

Engines

Electrical

(FCR).

Manual critical infonnation.

(ABYC)

sources

must

safety

your

equipment,

AND

gasoline

examination

standards

Systems

comply

tips

and

warnings

along

with

other

Read

and

follow

GENERATOR

engine or

of

the

American standards. including

These

the

USCG

of particular interest

with

the

Federal

are

repeated

cautions

your

manual

all

safety

and

INSTALLATIONS

generator standards

should

Boat

are

and

the

Code of

and

from

NFPA.

are:

ABYC, INSTALLING

Read the for safety tions

ABYC "Safety

Order

NFPA

"Fire Order

USCG· "USCG

Order

NFPA

following

codes

when

installing

(American

Standards

from:

ABYC 3069

Solomon'S

Edgewater,

(National

Protection

from:

NFPA 11

Tracy

Drive

Avon

Industrial

Avon,

MA

(United

33CFR183"

from:

U.S.

Government

Washington,

AND

DIESEL

and

MD

Fire Protection

Standard for

02322

States

D.C.

USCG

PUBLICATIONS

ENGINES

ABYC,

Boat and

for Small Craft"

21037

Park

NFPA

standards.

your

engine.

Island

Rd.

Coast

Printing

20404

Follow

Yacht

Association)

Motor

Guard)

Office

and

USCG

their

Council)

Craft"

FOR

pUblications

recommenda-

~

WESTERBEKE

Engines & Generators

iii

When

attention

installing

be

paid

WESTERBEKE

to

the

following

INSTALLATION

engines

information:

and

generators

it

is

important

that strict

CODES

Strict when

AND

federal

installing

REGULATIONS

regulations,

engines

ABYC

and

guidelines,

generators

SIPHON-BREAK

For

installations

or

will

be

break

in

the

minimum

the exhaust manifold injection port

water

damage

If

you

have

to

the

vessel's

siphon-break.

NOTE:.

A

siphon-break operation. engine

damage.

EXHAUST

The

exhaust

prevent

of

the

water

vessels

where

below

the vessel's

raw

water supply

of

20"

above

to

the engine and

any

doubt about

waterline

Failure

to

Consult

SYSTEM

hose

must from hull.

the

exhaust manifold/water injected

waterline,

hose

the

vessel's

possible

the

position of

under

the

requires

properly

entering the exhaust

periodic

maintain a siphon-break

the

siphon-break

be

certified

in a

provisions

to

the

waterline.

is

at or

vessel's

inspection

for

marine

under

and

safety

marine

environment.

must

exhaust

elbow.

Failure

below

the

flooding

various

of

the

water-injected

operating

and

manufacturer

use.

The

any

sea conditions and

codes

exhaust

be

made

'This

to

use

waterline

the

boat.

conditions,

cleaning

can

result

for

proper

system

must

be complied with

elbow

is close

to

install a

hose

must

be looped a

a siphon-break

will

result in

exhaust

elbow

install a

to

ensure

proper

in

catastrophic

maintenance.

must

be

designed

at

any

siphon-

when

raw

relative

angle

to

AVAILABLE YOUR

DEALER

FROM

WESTERBEKE

Carefully WESTERBEKE

Additional

review

the

Engine

manuals

Marine

or

Generator.

are

available

Installation

manual

from

your

WESTERBEKE

Engines & Generators

iv

provided

with

dealer.

your

TABLE

Parts

Identification

"on

Introductl

Warranty Procedures ......................................... 3

Serial Number Location ..................................

Fuel,

Engine

Admiral

Captain Preparations

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

Oil Control Control

for

Starting/Stopping

Engine Warning

Break-In

Lights,

Maintenance

S

Fuel

Cooling

ystem

FueI/Water Filter .............................................

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

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

System

Changing Coolant.. .........................................

Thennostat ......................................................

Raw

Water Intake Strainer ..............................

Raw Water Pump ............................................

Raw

Water Pump Parts Breakdown ............ 18A

Heat Exchanger ..............................................

Zinc Anode ......................................................

" L

E

ngme u rica

Ch

Changing the

Remote Water

b"

.

angmg.

Oil

Heater

th

Filter

Tachometer ........................................................

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

and

Coolant..

Panel

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

Panel

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

Initial

Start-Up

Procedure

Alarms

Schedule

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

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

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

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

and

Circuit

Breaker

....

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

t"

0"1

109 I ..................

0'1 F'lt 20

ell

Oil ........................................... 20

er

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

(Optional)

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

.....

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

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

OF

CONTENTS

.2

.4

l0

11

.12 Adjusting Idle Speed ........

14 14

14 15

16 17 18 18

11 20'

21

Alternator

3 Battery Care ....................................................

Glow Starter

5

6 7

8

9

Engine Engine Admirals Captains

En9ine

Control Panel Troubleshooting ......................

Engine

FuellRun Shut-Off Solenol .......................... .

D'

nve

E'

ngme m ...................................... .

'l'

~es

Oil Pressure Switch .......................................

Valve

CylinderHead Bolt Tightening .....................

Injection Timing ............................................

Fuel Injectors , ................................................

JS

and

9

Hurth

9

'..

P'RM

"S

Engme Lay-up Torque

22 24

Metric

Suggested

Testing/Troubleshooting

Plugs

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

Motor Wiring Wiring

Troubleshooting

ti' 0'1 Pressure 40

ng

HBW/ZF

N . T

,ewage

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

Diagram

Schematic Panel Panel

Wiring Wiring

(#39144)

(#39144) Diagram Diagram

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

Adjustments

Belt

AdJ'ustment

Co

1

Clearance Adjustment .........................

BWTransmissions

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

:d

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

pressl'on

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

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

Transmissions

""

ransmlsslons

f"

peci

and

Specifications Conversions

t"

Ica

Ions

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

Recommissioning

......

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

Oata

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

Spare

Parts

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

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

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

....

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

(#36844)

(#36467)

........................ · .... 3388

....

.........

...... : ....................

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

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

....

25 27

28

29 31 32

.33

34 35

.37

.38

39 39

..

.40 .41 .41 .42 .43

.44 .46

51

.

54

.

.56 .57

58 60

...v-

WESTERBEKE

Engines & Generators

1

PARTS

AIR

INTAI!E/SIILENCIER,

IDENTIFICATION

.••

U'~'"

PRESSURE

CAP

"iI~~:3r---

~

OIL

DRAIN

HOSE

i

FRONT

COOLANT

DC

PRESSURE

ALTE~NATOR

MOTOR

FILL

CAP

ENGINE

SERIAL

NUMBER

INLET

FUEL

PUNIP-,lbi~f:

FUEL

FILTER

REAR

TRANSMISSION

~

WESTERSEKE

EngInes & Generators

OIL

. J

SUMP

FILTER

INTAKEJSILENCE~

___

-.LIJ"~

UHIUN

PLUG

OIL

FILL

___

,

'RAW

WATER

PUMP

OIL

DIPSTICK

DRAIN

HOSE

2

This

WESTERBEKE WESTERBEKE's technology. dependable Thank

In

order

is

important manual manual throughout. your

This provided WESTERBEKE equipment WESTERBEKE'S

WARRANTY

Your folder. form registering writing number

We

take

performance

you

for

selecting

to

get

the

that

is

designed

carefully

Should

nearest

WESTERBEKE

is

your

operators

and a technical

contact

PROCEDURES

WESTERBEKE

If,

after

60

you

have

not

your

with

model

and

commission

Diesel

Engine

long

years

of

experience

great

pride

in

of

our

engines

WESTERBEKE.

full

use

and

benefit

you

operate

to

and

your

dealer.

your

installation

days

received a customer

warrauty,

information,

and

help

you

do

observe

all

engine

require

dealer

manual. A parts

manual

If

WESTERBEKE

Warranty

of

is

you

are

manual.

is

submitting

please

date.

is

a product

the

superior

and

from

maintain

this.

Please, read

the

safety

servicing,

for

assistance.

catalog is

available

planning

included

the

identification

contact

including

of

and

advanced

durability

generators.

your

generator

it

correctly.

precautions

also

from

to

install

dealer for'

in a

separate

Warranty the

factory

the

unit's

INTRODUCTION

This

this

contact

your

this

Registry

card

in

serial

and

it

PRODUCT

Product brochures

WESTERBEKE

CONTENT

RANTIES

THERETO, COMPLETENESS BE

LIABLE INCURRED OF

WESTERBEKE time

software

WESTERBEKE

provided WESTERBEKE be

relied the but WESTERBEKE

to

detennine

product

SOFTWARE

software,

THE

FURNISHING

span

and

with

upon respective is

imperati~e

software

(tech

and

catalogs),

are not within

CANNOT

OF

SUCH

OR

REPRESENTATIONS

INCLUDING

THEREOF

FOR

ANY

IN

CONNECTION

customers

between

printiogs

the

unavoidable manuals.

WESTERBBKE

or

I1ther

exclusively

product.

that or

the

accuracy

being

data,

parts

provided

SOFTWARE,

ACCURACY,

TYPE

OR

suppliers,

It

not

appropriate

supplier consulted

from

WESTERBEKE's

BE

RESPONSIBLE

AND

OF

DAMAGE

WITH

USE

should

of

WESTERBEKE

existence

In

summation,

products,

as

the

definitive

"uly

in

and

currentness

lists,

manuals,

sources

MAKES WITH

WILL

OR

OF

SUCH

also

must

makes

representatives

question

by

the

other

FOR

NO

RESPECT

TIMELINESS

IN

NO

OR

ARISING

SOFTWARE.

keep

in mind

of earlier

product whether

not

and

authority

good

sense

be

consulted

of

the

customer.

than

control.

THE

WAR-

OR

EVENT

INJURY

OUT

the

product

software from

cannot

on

of

Customer

Identification

IW

Customer

MR. MAIN

HOMETOWN, Model Expires

Identification

ENGINE

STREET

Card

WEStERSEKE

, Engines & Generators

OWNER

USA

Ser.#

NOTES,

As maintenance engine,

CAUTIONS,

NOTE:

A

CAUTIONS

this

manual

critical

An

operating

CAUTION:

observed, your

engine.

A

WARNING:

followed,

takes

schedules,

information

and

WARNINGS.

Procedures,

can

result

Procedures,

can

result

AND

WARNINGS

you

through

and

troubleshooting

will

procedure

in

the

in

personal

the

operating

of

your maline

be

highlight~d

An

explanatIon

essential

which

if

damage

or

which

injury

by

to

note.

not

strictly

destruction

if

not

properly

or

loss

procedures,

NOTES,

follows:

of

life.

'M7"

WESTERBEKE

Engines & Generators

3

INTRODUCTION

SERIAL

The engine's model and serial number are located a nameplate mounted

jacketed exhaust manifold. The engine serial number

also stamped into the out board

important information below, technical

NUMBER

of

as

this will provide a quick reference when seeking

infOrmation

LOCATION

on

engine

the injection

on

and/or ordering parts.

the side

of

the engine's water

block

on

pump.

Take time

the illustration

on

the flat surface

to

enter this

of

the namplate

iiiiijiiiiiiiiiii

Fill

in

the'

injo1711ation

UNDERSTANDING

The

diesel

engirie

the

since

are

same

has

rods Therefore,

same preventive

most important maintenance of Fuel

time contamination system consistent lubrication

The however, carburetor component'function of both.

mechanism

arranged

general

the

same

and

lubricating

and

lubricating

periods

is

also

use

diesel

in

to a great

oil

engine and

for

y~ur

THE

closely

is

essentially

above a closed

type

as a gasoline

types

of

valves,

system.

extent,

maintenance

factors

are

the

fuel,

lubricating and

filter

specified,

(water, essential. of

desigoed

its

ignition

the

and

sediment,

Another

the

same

specifically

does

differ

method

of handling and

systems

fuel

injection pump - which performs

reference.

QIESEL

resembles

crankcase. The crankshaft

camshaft, pistons, connecting

a diesel engine

proper ventilation

elements must be replaced

frequent checking for

brand of high detergent diesel

from

~

ENGINE

the gasoline engine,

the

same.

engine, and

as

a gasoline

cooling

etc.) in the

important

for diesel engines.

the gasoline engine,

firing

are replaced

The

cylinders

the

diesel

requires engine.

and

systems.

fuel

factor

of

fuel.

by

a single

the

The

proper

is

the

is

..

is

engine

at

the

The

the

ORDERING

Whenever engine the

silver

must

identify description separately packaged not

made

SPARES

Certain WESlERBEKE engine. will

assist

the

SPARE

Accessories, brochure.

INSTALLATION

Publication installing

.

PROTECTING

Care

.

have thousands manufacturer installed operated and serviced in buyer/owner·operator.

NOTE:

•

..•

PARTS

replacement parts

model

number

and

black name

provide

us

with

this

your

engine.

and

furnished parts to

the same

AND

spares

you

PARTS

see

In

part

number

Parts

because

ACCESSORIES

will

be needed

in

preparing

page in

WESlERBEKE'S ACCESSORIES

MANUAL

#43400

engine

provides

•.

' .

YOUR

at

the

factory

resulted in a WESlERBEKE

of

in

Six

important

Proper An efficient

an

anti-siphon break

during

hours

of

cannot

the vessel or

engine

well.designed

engine.

•

Changing operating

. •

Proper components this

the

hours.

maintenance

according

manual.

engine

are

needed,

and

serial

number

plate

located

information

addition,

for

List).

will fit

specifications

to

Your

an

this

de1hlled

so

include a complete part

each

part

Insist

upon

or

generic

as

support

local WESlERBEKE dealer

inventory

manual.

information

INVESTMENT

assembly

dependable

control

the

steps

to

installation

of

and

engine

service.

how

or

where

manner

field.

ensure

in

This

10llg

and

exhaust

to

prevent

o{[

and oil filters

all

engine

to

the

maintenance

always

provide the

as

they

appear

on

the

manifold.

we

may

needed

WESlERBEKE

parts are frequently

original equipment.

and

maintain your

of

spare

For Engine

thorough

capable of

However the

the

engine

which

the

is

up

to

the

engine

You

pro'perly (see

the

parts.

See

for

testing

many

is

unit

is

life:

alignment.

system

that includes

water

from entering the

every

100

and

generator

schedule

in

~Iii--DIIESI!L

PRE·COMBUSTION

CHJI,MBI:R~";:

•

FUEL

SPRAY

EngInes & Generators

•

4

Use

clean,

filtered

Winterize

Recommissioning"

your

engine

dieselJueL

according

section

in

this

to

the

manuaL

"Lay.up and

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

USE A DIESEL

(No.

Care

Use in your particles these

and unsatisfactory facilities.

engine's

advisable:

Purchase a

service a

.the

RMAM

ENGINE

Use a

CG-4, initial filter

SCHEDULE in

not synthetic using conventional MAINTENANCE SCHEDULE, not extended because

synthetic

SAE

For

The

by normal

FUEL

2·D

only

finely

keep

fuel

Of

fuel

tank

(SAE

The

clean

which

it To

daily

good,

are

WITH A CETANE

J313)

diesel

Fuel

Supply

diesel

fuel!

injection

finished

clean.

assute that

well-known

and

good

pump

might

parts.

The

by

careless

use

is

clean

visual-type

the

engine.

examples

pass

best

handling or improper storage

the

brand

RATING

fuel

according

The clearance of

is

very

critical; invisible

through

It

fuel

and

fuel

the

filter

is

important

can

be

rendered

gping

into

pure,

the

following

of fuel.Install

filter/water separator

The Raycor

of

such

filters.

OF

#45

to

ASTM

the can

to

buy

the tank

and

500

MA

OIL

heavy

duty

engine

oil

with

an

API

classification of

CH-4

or CIA.

50

hours

change

intervals

approve

or disapprove of

oils

OILVISCOSITY

all

temperatures

A

CAUTION:

engine

oil

to

additives

to

OIL

the

65

psi

of

produce

properties

PRESSURE

engine's oil pressure, during operation, is indicated

oil

pressure

operation,

2.5

and

Change

of break-in operation.

this

manual.

are

used,

oil.

are

used.

the engine

as

specified

Westerbeke

the

engine break-in

Oil

change

GRADES

use

SAE

lOW-3D

00

not

allow

mix.

Each

brand

different

3.9

brands

harmful

gauge

tl,e

oil

kg/cm').

1I0uid

on

the instrument panel. During

pressure will

Then

in

the

MAINTENANCE

use

of synthetic

must

intervals

or

two

or

more

contains

reactin

to

your

range

oil

and

follow the

Corporation

be performed

must be

l5W-40.

brands

its

own

engine.

between

OR

HIGHER.

D975}.

components

dirt

damage

clean

fuel,

for

practice

regularly

between

or

230

filter

after

oils.

as

of

a(lditives;

the

miXture

your

oil

does

If

in

35

is

CF,

an

and

the

and

ENGINE

WESTERBEKE and chemicals

The run the

cooling circuit from rust and corrosion. Look for a

quality Additives

balanced, The distilled water and

being

PURCHASING

Rather recommends

when

There

(green)

but

flush Premixed antifreeze for DIESEL Engines:

Specification

COOLANT

50%

distilled

that

antifreeze

at

proper

engine

to

antifreeze that

(SCAs)

crucial

poured

than

adding

are

two

and

do

not

mix

the

engine

recommends

water.

can

corrode

performs temperatures the

coolant,

contains

that

to

long term

into the

cooling

a mixture of

Distilled water

internal

double

duty.

by

transferring

and

lubricates

Supplemental Cooling

keep

the

antifreeze chemically

protection.

antifreeze

should

circuit.

is

engine

It

allows

50%

antifreeze

free

from

surfaces.

the

heat

away

and

protects the

be

premixed before

ANTIFREEZE

preparing

buying coolant

common

Propylene Glycol (red/purple), either can be used

#ASTM

the

two

and

thoroughly.

D53456.

mixture,

premixed

mixture

types

of

if

changing

WESTERBEKE antifreeze

will

antifreeze, Ethylene Glycol

always

from

so

that so that

be

one

MAINTENANCE

Change number protect

COOLANT

A coolant

the

engine coolant

of operating

and

lubricate

RECOVERY

recovery

engine

or

generator.

allow

for engine coolant

operation,

engine introducing

and

must

be

NOTE:

This tank, with its short run located at or above the level can be located below the level

particular installation

without

air

into

installed before operating

hours

the

engine

tank kit

The

purpose expansion

the

cooling

makes

every as

TANK

is

the

five

years

regardless of

the

chemical

have a limited

supplied

of

loss of coolant

system.

of

the engine's manifold, but it

of

the engine's manifold

this

necessary.

additives

life.

with

each

this

recovery

and

contraction during

and

This

kit

the

engine.

of

plastic hose, is best

the

engine

to

from

good

con·ect.

to

another,

the

that

tank

is

to

without

is provided .

if

the

NOTE:

A newly started,

reading upwards

have an oil pressure reading as

These readings will vary depending upon the temperature the engine. the load placed

cold

engine can have

of60

psi (4.2 kg/cm". A warmed engine can

lowas

25

psi

on

the engine,

and

an

oil pressure

(1.8

kg/cm".

the RPM's.

of

Engines & Generators

5

DESCRIPTION

This

manually-operated

KEY

switch

and

RPM

meter

which

measures

in

1/10

hours.

'The ATURE Fahrenheit. engine's control tem's

switch is

pushbuttons.

RPM TERS PER ENGINE RECALIBRATED ACCURACY

REAR

gauge

an

oil

pressure

circuit

voltage.

is

turned

in operation.

one

GAUGE;

REGIS-

REVOLUTIONS

MINUTE

OF

THE

AND

CAN

BE

FOR

FROM

OFTHE

THE

PANEL.

which

OIL

VOLTAGE All

on

The

for

control

gauge

the

engine's

panel

also

indicates

PRESSURE

in

pounds

gauge

gauges

are

and

remain

panel

also

PREHEAT

WATER GRADUATED ILLUMINATED TURNED TEMPERATURE

ADMIRAL

panel

is

equipped

with

an

ELAPSED

running

includes a WA1ER

water

gauge

per

square

which

illuminated

contains

and

TEMPERATURE

ON.

time

temperature

which

measures

inch.

measures

when

while

two

rubber-booted

one

for

START.

GAUGE;

IN

DEGREES

THE

ENGINE'S

IS

170'-190' F

FAHRENHEIT

KEY

WHILE

THE

with

a

TIME

in

hours

1EMPER-

in

degrees

and a DC

the

sys-

the

key

the

engine

THIS

GAUGE

SWITCH

NORMAL

OPERATING

(77' -66·C).

CONTROL

When the

PANEL

the

engine

water

temperature

.power

and

the

AND

IS

.

IS

was

when

the

key

will

once

again

electrical power A

separate

Admiral

necting

electrical the be running.

on engine's

Panel.

the

buzzer

audible

'The

and

should

oil

harness.

is

shut

reading

turned

off.

switch

indicated

is

register

is

restored

alarm

buzzer

The

installer

buzzer

to

the

'The

in a location

to

the

operator

buzzer

will

silence

pressure

rises

down

with

gauge

will

continue

by

the

'The

oil

pressure

turned

off.

the

engine's to

the

gauge.

with

harness

is

responsibla'for

four~pin

installer

where

sound

when

'OIL

ATEO ILLUMINATED ON. PRESSURE (2.1 -4.2

connection

is

also

it

will

should

it

when

the

engine

above

15

PRESSURE

THE

IN

POUNDS

ENGlNE'S

RANGES

kglem').

GAUGE;

WHILE

the

key

gauge

'The

temperature

Ime

temperature

is

supplied

responsible

be

dry

sound

the

ignition

has

psi

(1.1

THIS

PER

SQUARE

THE

NORMAL

BETWEEN

switch turned

to

register

the

before electrical

will fali

gauge

when

with

every

electrically

on

the

engine's

for

installing

and

where it

while

the

engine

key

is

started

and

kglcrn'J.

GAUGE

IS

GRADU·

INCH

KEY

(PSI)

SWITCH

30 -60

IS

OIL

psi

OPERATING

off.

last

to

zero

con-

will

is

turned

the

AND

IS

TURNED

HOURMETER; REGISTERS

TIME. USED

THE

SCHEDULE.

PREHEAT ALTERNATOR'S FUEL

ENGINE'S OIL BUTTON

START STARTER'S THIS UNLESS

AT

THE

--p;,..,

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

EXCITER.

SDLENOIO

GLOW

PRESSURE

ALARM

ENERGIZES.

BUTTON;

SOLENOID

BUTTON

WILL

THE

PREHEAT

SAME

TIME.

____

BE

FOR

ON

THE

PLUGS.

SWITCH.

THE

WHEN

PRESSED,

WHICH

NOT

BUTTON

PRESSED.

THE

FUEL

INJECTION

IT

OPERATE

LIFT

BYPASSES

IN

ADOITION.

START

BUTTON.

ENERGIZES

CRANKS

ELECTRICALLY

IS

PRESSED

PUMP.

_

ENERGIZES

PUMP,

ANO

THE

ENGINE'S

THE

ENGINE.

THE

THIS

THE

AND

HELD

'/..,

]1.

~

•

.

'

~

.••••••••

AUTOMATIC

COOLANT SUPP D HTHEINSTRUMENT

REACHES

WHICHWILlEMIT OIL

lOCATEOPFF

t~E5

ALARM.

ALARM

SYSTEM

TEMPERATURE

LIE

WIT

210' F (99·C),.THIS

A

PRESSURE

E~~rp~~(g~

AI.ARM;

THEENGiNE'S

!~.~S~~C~;)~~~~~~T~M~?~~~~E~~6~~~~~~\fteLL

IN

THIS

EVENT.

:

ALARf,,;

AN

PANEL.IFTHE

SWITCH

CONTINUOUS

AN

THE

SIGNAL.

Oil

PRESSURE

Oil

GALLERY.

ALARM

__-KI:Y

ALARM

BUZZER

WllLCeOSE

ALARM

THIS

WILL

EMIT

S'WITI~H;

POWER

ONLY INSTRUMENT CLUSTER.

DC

VOLTMETER; INDICATES BATIERY

IS

!iHOULD

SHOW

HAS

BEEN

ENGINE'S

COOLANT

.

SDUNOING

SWITCH

A

IS

MONITORS

PULSATING

PROVIDES

TO

THE

PANEL

THE

AMOUNT

BEING

CHARGED.

13V

THE

ALARM

SIGNAL

TO

THE

14V.

~

WESTERBEKE

Engines & Generators

6

DESCRIPTION·

This

manually-operated

KEY

switch,

an

RPM

tons,

an

INSTRUMENT

lamps,

one

for

AL1ERNATOR

OIL

PRESSURE,

TEMPERATURE.

RPM

GAUGE:

PER

MINUTE RECALIBRATED THE

REAR

OFTHE

and

REGISTERS OF

THE

ENGINE

FOR

ACCURACY

PANEL

REVOLUTIONS

control

gauge,

TEST

one

for

AND

CAN

FROM

CAPTAIN

panel

is

equipped

PREHEKf

button DISCHARGE,

high

BE

and

ENGINE

OIL

PRESSURE

ALARM

with

START

three

indicator

one

for

COOLANT

CONTROL

The

a

but-

low

PRESSURE

RPM

and

ALARM: BELOW

PULSATING

TEMPERATURE 210'F NOTE:

SOUNDING

PRESSURE

PANEL

panel

also

or

gauge

is

reniains

THE

5-10

SIGNAL.

(99'C). THE

ALARM

IS REACHES

illuminated

ALARM

psi

(0.4-0.7

IN

THE

IN

THIS

NORMAL.

includes

high

an

COOLANT

illuminated

while

WILL

SOUND

kg/em').

THE

ALARM

FRESHWATER

EVENT,

SOUND

ONCE

15

psi

THE

M~1

WILL

alann

buzzer

for

1EMPERATURE.

when

the

KEY

the

engine

is

IFTHE

ENGINE'S

IN

THIS

WILL

ALSO

COOLING

ALARM

WHEN

THE

ENGINE

k'g/em~,

THE

EVENT, SOUND

CIRCUIT

WILL

EMIT

KEY

STARTS

ALARM

OIL

THEALliRM

IF

A

SWITCH

AND

WILL

.

low

OIL

The

switch

js

turned

on

in

openition.

PRESSURE

THE

RISES

CONTINUOUS

THE

TEST

PRESSED, ALTERNATOR. PRESSURE, COOLANTTEMPERATURE CUITS. THE

OIL THE

TURE

LIGHTS ADDITION

ING BUZZER.

FALLS

WILL

COOLANT

IS

TURNED

SILENCE

BUlTON:

ALTERNATOR,

PRESSURE,

WATER

THE

EMIT

TO·

SIGNAL.

ON.

ENGINE'S

OIL

WHEN

TESTS

THE

AND

THE

CONTROL

INDICATOR

CIR-

WHEN

PRESSED.

AND

TEMPERA-

ILLUMINATE

TO

SOUND·

ALARM

A

THIS

OIL

THE

IN

LIGHT

START

BUTTON: STARTER'S BUlTON PREHEAT TIME.

WHEN·PRESSEO,

SOLENO,ID

WILL

NOT

OPERATE

BUTTON

IS

WHICH

PRESSED.AND

ENERGIZES

CRANKS

ELECTRICALLY

THE

HELD

THE

ENGINE.

UNLESS

ATTHE

THIS THE

SAME

·"IIY'WESTERBEKE

Engines··& Generators

7

ALTERNATOR'S SOLENOID

GLOW

PLUGS,

SURE

ALARM

GIZES

THE

.

---~--

BUTTON:

WHEN

EXCITER,

ON

THE

INJECTION

AND

BYPASSES

SWITCH.

START

IN

BUTTON.

KEY

SWITCH: POWER INSTRUMENT

CLUSTER.

PRESSED,

THE

FUEL

LIFT

PUMP,

THE

ENGINE'S

ADDITION,

PROVIDES

ONLYTO

THE

PANEL

ENERGIZES

AND THIS

PUMP,

THE

ENGINE'S

OIL

BUTTON

THE

PRES-

FUEL

ENER-

.

PRESTART

Before starting prolonged layoff,

o

Check at

OThman

examine contaminants.

o

Check

o

Check and

(+)

the negative (-) stud

o Check

and

INSPECTION

your

the

engine oilleve!.

the

high

mark

the

transmission

the

DC

battery

cable

battery

cable

(this

location

the

coolant

at

the

manifold.

engine

check

on

fuel

supply,

fuel

electrical

is

cable

filter/water

PREPARATIONS

for

the

following

Add

the

dipstick.

then

separator

fluid

system.

connections.

connected

is

connected

is

tagged).

level

in

both the

first

time

items:

oil

to maintain the

check

the

leve!.

Inspect

Make

to

the

to

plastic

or

after a

fuel

supply

bowl

for

wire

connections

certain

the

positive

starter solenoid

the

engine

ground

recovery

FOR

level

and

tank

INITIAL

NOTE:

refer

D

Visually parts, the

D Make certain

engine. perfonnance.

D

Make

START-UP

If

the

engine

has

to

the

COOLING

examine

disconnected

threaded

An

sure

the

wires,

connections

there

is

ample

supply

the

mounting

engine.

proper

D Ensure the propeller shaft

transmission.

D .

Open

to

the

TOP

the thru-hull

raw'water

'OIL

and

strainer.

FILTER

not

yet

SYSTEM

Look

and

unattached

and

engine

ventilation

is

necessary

installation

is

securely

make

certain

been

filled

with

coolant,

section

of

this

manual.

for loose

attachment~.

is

raw

hoses.

around

for

proper

secure.

attached

water is

or

missing

the

to

Check

engine

the

primed

CHECK

COOLANT

LEVEL

CHECK

TRANSMISSION

,

. I . .

FLUIO.

CHECK

ENGINE

OIL

LEVEL

LOW

~

WESTERBEKE

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

CHECKLIST

Follow

D

this

check list Visually Check Check

Periodically check

D

Check

D Check D

Look transparent

D Check

mounting

D Check

D

Check

D Check

secure.

STARTING

1. Put

2.

Tum

(The

3.

Depress

seconds

(The is

4.

Continue the

(The

5.

Release

6.

With

proper check water opens. is

inspect the the

the your

for clean

for

the drive

the

THE

the

transmission in

the·

KEY

panel

the

depending

fuel lift

activated).

START

start motor

the

oil

for overboatd

temperature

Do

ciose

to

NOTE:

Never

engine

is

It

is

important become immediate

If

allow

aware

a "smart"

about 50

is

pressing

engine

oil coolant

transmission

fuel

bowl.

loose

starting

raw

is

pressure

not normal.

running.

action

each

the

engine

level

(dipstick).

level

the

supply.

fuel

in

wires

secure.

batteries

belts

for

wear

water

pump

ENGINE

to

the

ON

energized,

PREHEAT

on

pump

is

priming

the

BUTTON.

is

cranking

START

BUTTON

running,

and

discharge

will

engage

attempt

to

closely

of

the

if

these

regulator

seconds

day

before starting your for

fuel,

oil,

or

water

in

the

coolant

manifold

fluid

level.

the

fuel

filterlwater separator

at

the

alternator

(weekly).

and proper

to make sure

neutral

position

gauges

BUITON, hold

how

cold it

the

PREHEAT

the

check the instruments for

battery charging rise

slowly until

the

gear shift until

to

engage

monitor

normal

readings

is

part

for

the

engine

recovery

coolant

and

tension

and

advance

(2

o'ciock).

are

lit).

is.

engine

BUTTON

engine).

as

the

engine

of exhaust

the

starter

the

panel

readings

start

of

the

charging

RPM

gauge

level.

its

for 5 to

and

voltage.

water.

the

to

engine.

leaks.

tank.

make

sure

(weekly).

mounting

the

throttle.

15

the

preheat

and

press

starts.

Also

The

thermostat

temperature

while

the

gauges.

and

vary.

system,

to.

activate.

its

take

is

FAILURE

If

the

seconds,

5 procedure. neutral

Never

engine fails

CHART

A

engine

filling

pump

cooling enter manifold

from

through-hull

correcting.the Engine

warrantable

in

STOPPING

To place the transmission a

the shut-off teelknob out Then push with

NOTE:

the

FAILURE

In

engine off

accomplished adjacent

maym,edto be thu:aded into the block an additional

y.

TO

START

engine

fails

to

start

wait

for

at least

Make

certain the

position ..

run

the

starter

motor

to

start.

refer

in

this

manual.

CAUTION:

with

is the

happening

Prolonged

starting

raw

pumping

system

engine's

once

the

can

result

water.

raw

water

during

cylinders exhaust

by

closing

shut-off;

cause

of

damage

resulting

issue;

the

mind_

PROCEDURES

stop

the

engine,

few

moments

the

key.

Units

key.

TO

the unusual situation that

and

to

NOTE:'

In such,cases the electric fuel

-

V.

turn.

bring

in

to stabilize the

shut-off

with

STOP

by

the throttle lever

the

it

stays

manually

tee!knob

Optional

(Optional

at a low

when

the

start button is

30

seconds

transmission

for

to

the TROUBLESHOOTING·

cranking

in

This

may

cranking.

system the

draining

the

from

owner/operator

the

throttle

·neutral. and

allow

the

working

by

and repeat

control

more

than 30

the

engine

happen

through

This

by

way

raw

the

ellcessive

raw

seconds.

intervals

exhaust because

the

raw

water

of

the

exhaust

fills.

Prevent

water

supply

exhaust

engine

water

entry

without

muffler,

should

to

an

idle

Allow

the

engine

temperature.

the engine

back in

Electric

·key

switch

idle,

shut down

the shut off lever located

the

injection

to

fully

and

Shut-Off,

Shut-Off)

fails

pump.

sltut

water

position and

off soleuoid .

pressed

the

is

cranking.

keep

can

starting

in

the

If the

the

system

the

can

this

and

is

not

this

to

idle for

Then pull

stop

fully.

shut-off

just

turn

to

tum the

be

for

a

off

NOTE:

VQltage

A

when

the

is

depressed.

When

starting:

drop

will occur

preheat·switch

ENGINE

Engi,.,e$

9

STOP

LEVER'

& Generator$

DESCRIPTION

Altliough hour of assembly ated your

. and

Breaking-in a new ton and scored, break-in

Your conditioning to Pelionn lowing:

1. Start

2.

your

test

procedures were

properly,

engine

serviced

rings

to

smoky

which

period.

new

engine

maximize

this

the

DURE

that

all

charging) Allow

the engine

fast

idle)

the

130

engine has experienced a

operations

a break-in time

is dependent

during its initial 50

the cylinder

operation indicate that

is

caused

operation the performance and conditioning

engine according to section. systems

are functioning.

until

- 140'F

at

the

factory

to

followed

upon

engine basically

walls.

by

overloading the engine

requires

approximately

to

break

carefully,

Run

the engine at fast idle while

(raw

water

to

warm

the

water temperature gauge

(55

- 60'C)

and

is

required.

how

the engine

hours

involves

Excessive

the

in

each

service

keeping

the

pump,

up

(preferably

range.

ENGINE

minimum

make sure accurate

that

The

of

use.

oil

cylinder

50

moving part in

life of the

STARTING

oil

pressure,

BREAK-IN

of

one

the

engine

service life of

is

operated

seating the consumption

walls

are

during

hours

of

initial

order

engine.

in mind the

PROCE-

checking

battery

by

running

moves

into

oper-

pis-

the

fol-

at

PROCEDURE

3.

While

using

the

vessel,

speeds

for the

first

25

hours.

idling.

4.

Avoid

rapid

.acceleration,

5.

Use

caution grey reach

,6.

During the vlUying Avoid

CHECKLIST

D Moniior

D .

Check

D

Check

vibration

D

Confirm

When When

When

NOTE:

See

break-in

not

to

overload

or black

its

information

exhaust

full

rated

prolonged

the

control

for

leaks

for abnonnal

and

exhaust

the

engine

the

engine

ihe

engine

the

TRANSMISSION section

and

speed

25

hours,

speeds,

idling

panel

of

fuel

noise

blow-back

smoke:

is

cold

is

wann - almost

is

overloaded -some

on

your

run

the

engine

Avoid

especially

the

engine.

the

inability

are

signs

the

engine

with short

during

this

gauges.

and

engine

such

sounds.

- white

transmission.

at

various

prolonged

with

a cold engine.

The

of the engine

ofan overload.

may

be operated at

runs

at

full

break-in

oil.

as

knocking,

smoke.

smokeless.

black

of

this

engine

pedods

presence of a

to

rated

rpm.

pedod.

friction,

smoke

and

soot.

manual for

of

Engines & Generators

10

.

WARNING

LIGHTS,

ALARMS & CIRCUIT

BREAKER

ALTERNATOR

The Captain Control

red warning light.

with a The Admiral Control

performance

--"

-

ENGINE

The

DC mounted manual reset circuit breaker Excessive current the instrument breaker pump

engine for

Reset the breaker

to

will tenninate.

will

the

cause of high current

WARNINGS

of

the

.-

CIRCUIT

hamess

trip.

slow

on

draw

panel

fu

this

and

Panel

indicates

Panel

uses

a voltmeter

alternator.

BREAKER

the

engine

is protected

or electrical overload

wiring

or

engine wiring

event

DC

power

As

fuel

is

consumed

stop.

If

this breaker should

draw

and repair the

re-start

the

engine.

alternator

by

(20

amps

to

the

and

low

discharge

to

monitor

an

engine

DC).

anywhere

will

cause the

electric fuel

runs

out,

trip,

check

problem.

the

THIS IS

ONLY

COI!TRQ~

WATER TEMPERATURE· ' ,.

SENDER

in

the

COOLANT

A coolant housing; coolant's

(99'Cl.

COOLANT

AVAILABLE

LOW

A block.

sure. (0.4-0.7 alarm.

This

operating

TEMPERATURE

PANEL

.

(COOLANT)

,-

OIL

low

oil

pressure

This switch's sensor monitors

Should

kg/em'), this switch

TEMPERATURE

temperature

switch

WITH

..

PRESSURE

the

switch

is

will activate a continuous alarm

temperature reaches approximately

SENDOR

THE

AOMIRAL

ALARM

alarm

switch

engine's oil pressure

will

SWITCH

located

on

the thermostat

SWITCH

is

located

activate a pulsating

on

the

engine's oil

fall

to

the

5 -

engine

10

psi

if

the

~J!Ff

pres-

OIL

Eng/nes & Gen,erstors

11

PRESSURE

SWITCH

In

order to

to log

your

engine

NOTE:

Many

simple

but

knowledge

use

this

engine

hours

of

others

of

a service

Maintenance

hours.

by

running

the

following

are

more

mechanic.

Schedule,

Use

your time.

maintenance

difficult

MAINTENANCE

it

will

be

necessary

engine

and may

hourmeter

procedures

require

or

the

record

are

expert

SCHEDULE

A

WARNING:

while

the

equipment

correct terminals electrical

tools

Never

engine

is

running.

such

as

goggles

for

each

when

servicing

equipment.

attempt

job.

to

perform

Wear

the

and

gloves,

Disconnect

any

of

the

any

proper

and

use

the

battery

engine's

service

safety

the

DC

SCHEDULED

MAINTENANCE

Fuel

Supply

Filter/Water

Engine

Coolant

Transmission

Drive

Visuallnspeclion

Fuel Starting

(and

Engine

Heat

Filler/Water

Exhaust

Engine

Throttle

Shut-Off

Adjust

Raw

Inlet

Separator

011

Level

Fluid

Bells

Filter

Batteries

House

Batteries)

011

and

Exchanger

Separator

System

Hoses

Transmission

Cables

Engine

Idle

Water

Pump

Fuel

Filter

Level

of

Engine

Zinc

Speed

Anode

CHECK

EACH

DAY

D D

D D D

D

weekly

D

weekly

HOURS

OF

OPERATION

50

100

NOTE:

Keep

oil

will

inhibit

cool.

0

250 . 500

engine

surface

the

engine's

D D D D D

750

clean.

ability

1000

Din

to

D D D D D D

0 D D D D D

D D D

0 D

0 D D

D

D D

D

D D

D D D

D

D D

D D D D

1250

and

remain

D

D D

D

Diesel

No.2

Check

for

water

if

necessary).

Oil

level

should

dipstick.,

.•

Check

at

recovery

Add

coolant

Fluid

level

on

dipstick.

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Change

at

Check

electrolyte

and

make

excessive Initial

engine

change

both

Inspect

zinc

exchanger Change

filter

Initial

check

Inspect

for

tion.

Check corrosion replace

as

tight.

Check

Hose

should

spongy.

Check

for

Lubricate Adjustto

Remove gasket,

cam

and

seals

Lubricate

Replace.

MAINTENANCE

rating

and

indicate

if

neeii~d.

should

proper

if

needed.

fuel,

oil

connections.

loose

belt

50

hours

sure

connections

corrosion.

oil & filter

every

anode,

end

of

every

at

50 leaks. the

exhaust

buildup

necessary.

castin'g

be

hard & tight.

and

loose

fittings,

with

WD-40

1000

-1200

the

pump and

(the

shaft

when

DESCRIPTION

of

45

cetane

dirt

in

fuel

between

tank;

if

empty,

indicate

between

tension

(3/8"

Check

belt

and

water

leaks.

Keep

tension. then

every

levels

every

are

change

100

hours.

replace

if

zinc

anode

200

hours.

hours,

then

Check

anti-siphon

elbow

on

inside

Check

integrity.

tighten

all

cotter

or

equivalent.

rpm

cover

and

cover

for

wear.

can

turn,

reassembling.

or

higher.

(drain/replace

MAX.

and

check

at

MAX

and

to

112"

deflection)

edges

for

Inspect

bolts & nuts

250

hours.

50

operating

very

tight.

at

50

hours,

needed.

Clear

debris.

every

250

hours.

valve

for

carbon

passages;

that

Replace

cl.ean

alLconnections

"

if

soft

hose

clamps.

pins,

etc.

inspect

the

Check

the

but

not

wobble).

filter

LOW

on

manifold.

LOW

wear.

wiring

tight.

hours

Clean

off

then

the

heat

opera-

and/or

and

are

or

impeller,

bearings

.

(continued)

Engines & Generators

12

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

by

running

hourmeter

time.

gauge

SCHEDULE

to

log

your

engine

hours

of

record

your

SCHEDULED

MAINTENANCE

Raw

Water

Pump

At

750

operating

disassemble

overhaul.

Coolant

Electric

'Fuel

'Starter

'Preheat

'Engine

Compression

'Adjustthe Re-torque

'Heat

'Water

Elbow

Engine

Lubricate

with

Transmission

and

System

Fuel

Lilt

Injectors

Motor

Circuit

Cylinder

Valve

Cylinder

Exchanger

Injected

Damper

Panel

II

LDckeze"

hours, inspect

for

Pump

Clearances

Head

Exhaust

Plate.

Key

Switch

Fluid

Boils

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

1000

D

D D

D

D D D D D

D

D D

.

D D

D D D

D D

D

1250

Remove and components for

Drain, appropriate

MAINTENANCE

the

pump

inspect

all

components,

as

needed.

wear.

Replace

flush,

and

refill

antifreeze

Periodically Inspect

Check

spray

Gheck.sqlenoid

and pinion

Check

·clean Reinstall

Check (see

Adjust bolts.(see

Remove,

tested.

Check operation.

needed.

Chattering

damper needed.

Lubricate

Initial season.

check

the

fuel

line

and

adjust

condition.

and

lubricate.

ENGINE

Clean

drive.' operation

glow

plugs,

with

anti-seize

compression

ADJUSTMENTS).

Valve

Clearances,

ENGINE

have

professionally

casting

Integrity

Clean

at

idle~ow

plate

spring

at

50

change

at

(see

of

hours,

DESCRIPTION

from

the

engine.

Disassemble

replacing

Inspect

the

drive

gear

as

needed.

cooling

system

mix.

the

wiring

Lonnections

connections.

Injection

internal

25

opening

pressure

ENGINE

ADJUSTMENTS).

motor

for

corrosion.

and

lubricate

~1

preheat

check

resistance

compound

pressure

re-torque

ADJUSTMENTS).

every

rpm

wear.

then

hours,

the

solenoid.

and

timing

cylinder

cleaned

500

hours

passage.

is

an

indication

Inspect

at

least

then

at

Replace

(4-6

on

and

once a season.

least

all

worn

gear

with

the

and

Remove

starter

motor

Remove

ohms).

threads.

head

and

pressure

of

as

of

replace

once

slot

and

as

a

'WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

13

'FUEL

SYSTEM

DIESEL

USE A DIESEL

(No.

FUEL

The

manufactnred from must separator clean, schedule in

FUEL

A installed between the water be,

The fuel impurities. maintaining a proper fuel

10

FUEL

2-D

(SAE

FItTERS

fuel

injection

water

and

pass

through

and

change these

this

WATER

primary

fuel

and

other

carried

to

the

owner/operator reaching

tank

micron

the

This

and

the

(no'finer)

WITH A CETANE

J313)

pump

and

they

dirt.

at least

the

engine's

manual.

SEPARATOR

filter

contami)lants

fuel

engine's

process

gerierator/engine.

diesel

fuel

and

the

must

receive clean

To

ensure

two

spin-on

filters

of the watef

fuel

tank

'system

on

is

responsible

injection

is

accomplished

fuel

filter

be

used.

RATING

according

fuel

injectors

this

flow

fuel

filters,

fuel

according

separating

and the

from

the

engine.

for

maldng

equipment

OF

#45

to

AStM

are

diesel

of clean

a fuel water

filter.

Visually

to

the

type

engine

fuel

before

certain

is

hy

installing

OR

HIGHER.

D975}.

precisely

fuel,

free

fuel,

the

inspect,

maintenance

must

be

to

remove

they

can

.

the

free

of

and

between

the

fuel

ENGINE

Periodically check leakage. then

-Changing/cleaning

1. Shut off the fuel

2.

3.

4. Replace the sealing

a

FUEL

FILTER

the

fuel

connections

Replace

follow

Unscrew housing housing,

Remove

to

the housing. Thread the retainer ring

,SO

as

not to cross

"0"

ring, tighten

ID!PPlY

the

filter

element after

the

MAINTENANCE SCHEDULE.

the

filter

element

supply.

the retainer ring that

and

allow

the

bowl

and replace the

"0"

1bread.

1/4

-

and run the engine

holds

to

coine

filter

element

ring and reassemble the

When retainer contacts the

112

turns to

inspect for leaks.

by

and

the bowl for

the

first

the

filter

away

and

on

hand.

from the

clean the

50 hours

bowl to the

bowl.

bOWl

carefully

Open the fuel,

LIGHTLY

FILTER

WITH

CLEAN WHEN THE

NEW

WIPE

INSTALLING

FUEL

CARTRIDGE

FUEL

The

fuel

injection

of

the

diesel

The

fuel

injection

the

and

it.

authorized attempt

The the speed

ADJUSTMENTS). '

owner/operator

If

it

requires

to

only

adjustment

fuel

injection

(see

pump

engine,

fuel

disassembly

IDLE SPEED ADJUSTMENT

requiring

pump

servicing, injection

the

pump

TYPICAL FUEL

'

FILTER

(OWNER

is the most important component

the utmost

has been

is

cautioned remove it

pump

and

servicing

is

the adjustment for

service

repair

thoroughly

-not and

it.

mechanic

caution

to

attempt

take

facility.

under

IIlSTALLED)

in

handling.

bench-tested

to

service

it

to

an

Do not

should

make

the

engine

ENGINE

to

idle

FUEL

LIFT

PUMP

INLET FILTER

FUEL

Periodically

and are pump's the_mounting

When purge

of

INLET

,,1'0 line,

filter

once a season,

FUEL

THE'D-RiNG ONLY

,.

REPLACfD SIGNS

LIFT

PUMP

check

the

fuel

connections

make

sure

that

no

leakage

tight

and

secure.

The

DC

ground

mounting

energized

air

from

fuel

as

the

FUEL

,nsure,cleanfuel-into the fuel

fuel

filter

should

bolts

sholjld

boltto

ensure

proper

thrn

the preheat

the

fuel

system

engine

is

running.

FILTER

connected

be replaced every

which

ever

to

the

occurs

NEEDS

OF

is

present

be

clean

pump

circuit,

and

provide a

pump,

fuel

250

n M""" 'it

TO

IFfT

AGING.

to

and

that

connection

and.

well

o'petation.

the;fuellift pump

continuotis

there

lift

pump

hours

of operation

first.

out

the

at

secUred

is a

elbow.

.

me

fittings

one

" '

small

pump

of

by

flow

This

or

FRESH

the

will

in-

FUEL

"IIY'

WESTERBEKE

~,?gines

14

& Generators

ENGINE

COOLING

CIRCUIT

OEseRIPTION

Weslerbeke marine ¢quipped

¢ngine

water coolant which circulates throughout the engine.

. ¢irculating fresh water

internal

the

¢xchanger; similar in water wesh water coolant

~erred

tube walls

for

by

combustion

meving parts.

fresh

water coolant

flows

to

the fresh water

to

diesel

generators are designed

fresh water cooling.

and

friction

coolant

The

heat

to

raw

function

through

the raw

the

flows

water

tubes

around

coolant

which

Heal

produced

is

transferred

cools

the

engine block

is

transferred externally

water

by

means of a heat

to

an

automotive

of

the

heat

exchanger while

the

tubes; engine heat trans-

is

conducted through

is

then

pump~d

-""'.

''-......

..

,

in

to

radiator.

----

and

the

fresh

This and

from

Raw

Ihe

into

the

..

--.....:..

exhaust other coolant transferred fresh each

its

----.

other. allows harmful

NOTE:

tion

for used'as the

fresh

..

'-

system where

words,

the engine

is

cooled by

heat overboard through

water coolant

Using

the

cooling water passages

deposits.

Refer

to

the

recommended

the

fresh

water

raw

and

only

ENGINE

water

system.

finally

it

is

discharged

is

cooled by

water,

raw

water

fresh

water coolant wilhin the engine

COOLANT paragraphs in this sec-

antifreeze

coolant

and

fresh

the

circuits

10

and

for

overboard.

water coolant, this

raw

water carries the

exhaust

slay

system.

are

independent

Clean

and free from

water

mixture to be

information on filling

In

The

.

of

EXHAUST

TYPICAL

COOLING

CIRCUIT

ASSEMBLY

DIAGRAM

NOTE:

AN

VALVE

MAY

HEAT EXCHANGER

ANTI·SIPHON

BE

REQUIRED

FRESH

WATERy

RAW

WATER

*

...

WESTERBEICE

Engines & Generators

15

FRESH DRAIN

DRAIN

WATER

COOLING

SYSTEM

FRESH

Ftesh

'circulating pump,

coolant

to engine When

prevented

flow

manifold

thermostat

coolant

cooling

ENGINE

WESTERBEKE

and

chemicals The

to

the cooting quality Additives anced,

The

WATER

w:at~r

then

the

heat

block via

the

is

bypassed

to

system

50%

antifreeze

run

at

engine

circuit

antifreeze that

crucial

NOTE:

Lookfor

antifreeze

recommended

against

the

will

also

the

circulating

A

proper

engine

coolant

passes

exchanger

engine is

by

the

from

overheating).

gradually

flow

unrestricted

.•

COOLANT

distilled

that

can

performs a double

proper

to

the

from

(SCAs)

to

that

is

most

retard rust

pump

50/50

to

COOLlN.G

is

absorbing

through

the

suction

started closed around

recommends a mixture

water.

corrode

temperatures

coolant

rust

that

long

the

new

now

50/50

extreme

within

mixture

temperatures

I;I{lCUIT

pumped

where

opens,

contains

keep

term

available.

impeller

through heat the

.thermostat

it

is

cooled

side of

cold,

external

thermostat

the

thermostat

As

the

allowing

to

the

bistilled water is

internal engine

by

transferring

and

lubricates and

and

corrosion.

Supplemental

the

antifreeze

protection.

environmentally

mixture will temperature.

the

engine

and

as

recommeI!ded

of - 40'F.

from

the

(although

engine

external

duty.

seals.

the

engine

the

engine.

into

and

returned

circulating

coolant

to

prevent

warms

full

flow

portion

of

50%

free

surfaces.

It

allows

protects

Look

chemically

friendly

protect The

antifreeze

and add

will

by

The

the

manifold,

pump.

flow

some

coolant

the

up,

of

the

of

antifreeze

from

the

engine

heat

away

for a good

Cooling

long

the

engine

to

the life of

protect

a

to

the

is

exhaust

the engine's the

from

the

bal-

lasting

mixture

the

·NOTE:

Periodically

Ensure

thot condition tightly.

and

Carry a spare

CHANGING

The

engine's

MAINTENANCE

become

Drain cent heat jacketed

Refillil1gthe.;~oolant

After into

Monitor

the

to

the

exchanger

closing

the

manifold

flowing, Remove

coolant

cap.

the flow

into

After

checking Coolant engine needed.

contaminated,

engine

oil

exhaust

manifold,

the install

the

mix

Run

the

should

cools

Clean

check

the

upper

and

check that

the

cap.

COOLANT

coolant

must

SCHEDULE.

it

can

coolant

filter,

and

manifold.

BLOCK

. .

COOL

DRAIN

by

remove

·remove

~

@'ii

the

engine

drains,

start

the

coolant

in

the

to

the

filler

the

pressure

cap

on

the coolant recovery

to

halfway

the

recovery

for

down.

up

engine

leaks,

draw

Add

any

between

tarik.

back

spilled

neck

and

coolant

condition

lower

vacuum

be

changed

lead

removing

the

\

'i

1:;:::-

of

the

pressure

rubber

seals

are

valve

opens

according

If

the

coolant

to

overheating

in-board

pressure

4/)J~

is

allowed

the

block

drain

plug

cap

from

. & .

(f(~~

0$

'l~

. 0

1 .

pour

engine

manifold

and

cap.

observe

stop

the engine

into

the cooling

coolant

clean,

and

when

LOW

the

to

the

preri:rixed

run

it

at a slow

add

the

coolant

tarik

and

MAX

coolant

and

system

recovery

~

as

needed.

and

allow

in

good

and

to

the

problems.

on

the

~?~

fill

and

expansion

as

tarik

cap.

closes

to

adja-

the

water

,

coolant

idle.

Fill

is

with

replace

it

to

the

if

cool.

Coolant

The

traction outintroducing air provided

water operating

.

NOTE:

located

Recovery

coolant

of

the

with

coolant

the

This

tank,

at

or

recovery

engines

into

fresh

water

conversion

engine.

with

above

the

Tank

tarik

allows

coolant

the

cooled

kit

its

short

level

during

system.

and

must

run

of

the

for

the

engine

This

models

be

of

plastic

engine's

expansion

recovery

and

installed before

aJ!d

operation

tarik

with

the

hose,

is

manifold.

con-

with-

is

fresh

best

ElJ.gJn_t!~

& Generators

16

A

CAUTION:

down

before

the

sud

ace

can

be

at

A

CAUTION:

The

attempting

of

the

engine

190'F.

Proper

engine

critical; a substantial tracedbackto

cooling

"",ust

these

procedures.

hot

but

cooling

number

of

lIystem

be

allowed

coolant

system

engine

temperatures

maintenance

failures

corrosion.

to

Not

cool

only

can

is

is be

THERMOSTAT

A

thennosta~

engine, continuously the

engine coolant hole

in

overheating).

gradilally

checked,

and

gasket

A

coolant

and

contraction

cant

loss

ing

system.This·

engine

TO

RECOVERY

located

controls

from

the

manifold

COOLANT

the

flows

is

first

flowing

thermostat to

As

opens.

cleaned,

recovery tank

of coolant

TANK

coolant

through

started,

the

engine

The thennostat

or

during

and

tank

level

near

the

temperature the

the

(some

prevent

warms

replaced

allows

engine

without

should

and

should

manifold

closed

cooling

closed

thennostat

coolant

is

the

exhaust

up,

is

accessible

easily.

Carry a spare

for

engine

operation,

introducing

be located

be

easily

KEEP

THE

by-passed

the

COOLANT

CLEAR

COOLING

at

the'

front

as

the

coolant

circirit.

prevents

t)rrough

manifold

thennostat

and

can be

thermostat

coolant

without

at

PASSAGE

any·signifi-

air

into

or

above the

accessible.

of

the

When

a

from

expansion

the

cool-

SYSTEM

.

THERMOSTAT

'ASSEMBLY

FROM

COOLANT

RECOVERY

Replacing

Remove housing gasket,

gasket

cap

Run there

TANK

'the as

apply

before

screws.

the

engine

are

uo

the

cap screws

shown.

leaks at

Thermostat

and

disassemble

When

instaJJingthe

a thin coat of sealant

pressing it

and

into

check

the

thermostat

for

place.

normal

the

..

ii:ew

on

both

sides

Do

not

over-tighten

temperatures

housing.

thermostat

of

the

and that

and

the

HOUSING

A

CAUTION:

doWn'

before

attempting

is

the

surface

temperatures

of

can

The

the

be

engine

these

engine

at

190'

must

be

allowed

procedures.

hot

but

coolant

F.

to

Not

cool

only

Eng/nilS & Generators

17

RAW

WATER

The

raw non-ferrous has

flexible

within

the

On

no account should this pump be

always

be a spare

(an

impeller

when

lubricant operation. are

cautioned start-up. peiipdjcally

MAtNI'ENANCP;

NOTE:

Shoultr

(seals

and

p~rc1ulse

. a

spare.

water

pump

housing

blades

impeller

kit);

Such

to

The

raw

for

afailure

bearings),

a

new

PUMp·

is

a.,self-priming,

and a Neoprene

which

housing,

impeller

Raw

water

(raw

water)

fat1ures

broken

are

tnllke

sure

water

pump or

S9HEDULE.

occur

it

may

pump

and

wipe

against a curved

producing

and

impeller

pump

impeller

is

not

present

not

warrantable,

raw

water

should

tom

impeller

with

the

be

more

rebuild

the

rotary

impeller.

the

pumping

run

dry.

cover

failures

during

flow

is

be

inspected

blades.

pumps

cost

efficient

original

COOLING

SYSTEM

..

pump

with

a

The

impeller

cam

plate

.

action.

There

should

gasket

aboard

occur

engine

and

operators

present

at

See

.

internal

to

pump

parts'

as

·RAW-wATERJ'llMP(wu,Y"MODELsj

SAME

Impeller

#034440

NOTE:

must

They

INSTRUCTIONS

Kit

[{any

of

the

be

found

to

prevent

often

can

be

SCREW

,

SLOT

vanes

founil

APPLY

THE

IMPELLER

WITH

IN

THe

SHAFT

have

broken

blockage

iii;

the

heat

..

,~:--,

THE

off the

in

the

cooling circuit

exchanger.

impeller

tliey

..

:.;.

ImpellerKit

FITTING

SCREW

SLIDES

INTO

SHAFT

SLOT

INSPECTION:

,

EACH

BLADE

.

REPLACE ARE

ANY

WHEN THE

IMPELLER

KEY.

FOLD

EITHER

THE

CORRECT

IMPELLER

CHANGING

Close

the raw water intake

and

gasket

ers.

Carefully

coat

the

inside

the

new

impeller

intake

valve.

•

IMPELLER

CHECK

AT

BY

BENOiNG

THE

IMPELLER

CRACKS

•.

INSTALLING:

THE

DIRECTION

STARTS

THE

or

TAKE KEYWAY IMPELLER

(THEY

POSITION

TO

RAW

O-ring

pry/pull

of

the

aod

#048500

THE

.'0"

VIGOROUSLY.

IF

THERE

CARE

WITH

THE BLAOESIN WILL

WHEN

ROTATE).

WATER

valve.

with

the

aid

the

impeller

pump

housing

cover

with

ni,'"

TO

AUGN

SHAFT

TURN

THE

PUMP

of

out

gasket,

IN

IMPELLER

Remove

tWo

screwdrivers

of

the

with

glycerine,

open

RAW

WATER

PUMP'

#048080·

the

pump

cover

or

pli-

pump.

Lightly

InstaU

the raw water

RAW

WATER

A

cleao

raw

water engine's strainer

in

Perform

the

cooling

when

glass

the

should

following

operation:

1.

Close

the

2.

Remove

3.

Clean

tile

4.

Replace

5.

Reassemble

6.

Open the seacock .

7.

,Roo

the

NOTE:

Also

follow

ag1'rJund.

If

the

engine

normal

reading,

may

have

been

raw

water

through

NOTE:

Always

the

strainer

TYPICAL

INCOMING

INTAKE

intrus:e:strainer

sysfum.

nuiking

aod

glass

the

engine

temperature

will

raW

clean

washer

aod

the

caught

install

always

your

be

clear.

water

.

install

and

the

cause

the.

the

RAW

(OWNER

STRAINER

is a vital

Include a visual

pedodic

maintenance

Beacoelt

the

strainer

if

necessary.

the

check

above

gauge

may

up

ill

cooling

strainer

be

self-printing.

WATER

after

..

filtet

strainer.

for

leaks,

procedure

ever

be

that

the

strainer,

system.

at

INTAKE

INSTALLED)

component

inspection

engine

check.

every

100

after

having

shows a higher

silt,leaves

slOWing

or

belo~

the

STRAINER

.

of

the

of

this

The

water

h6.urs'

of

rnll

hard

than

or

grass

the

flow

waterline

,

of

so

NOTE:

Never

allow

the

pump

to

rnn

dry.

of

dry

rnnning

may

destroy

the

impeller.

Even a short

~WESTERBEKE

period

,

SEACOCK;,..·

Engl!J~-4~en!Jrators

18

"""''''''''''

INSPECT

AND

GLEAN

EVERY

100HOURS

FI~TER

!l'

~"',.'

"~_c'-"l~"

...

'

·a

til

...

••..•

'

........

!II

••

CO ~ ",

..... iQ

....

-,

..

=,.

i':J'

~'.,

'CD

_

'iI

,-,t'

',S

~.

:CiJ',m·

ALlGNjSLOrJNtrJ

OOWE~

NOTE

THE

PUMP-REPAIR

KIT

(49000)

INCLUDES

ALL

THE

USTED

CDMPQNENTS

EXCEPT

ITEMS

1

AND

7.,

THE

KiT

ALSO

INCLUDES'

A

PUMP

MOUNTING

GASKET.

ASSEMBLED

VIEW

EXPLODED

VIEW

'IMYt:LLt:If

PlffFITS

INTO

THE

SLOT

IN

THE'SHAFT

1

REPAIR

PARTS

ARE

AVAILABLE

FROM

YOUR

WESTERBEKE

DEALER

KEY

NO.

PART

NUMBER AND'PART NAME QUANITY '

1 48080

RAW

WJ!(fER

PUMP'

1

2 ,49172 SHAFT 1

3 49170 IMPELLER COVER 1 4

48500 IMPELLER KIT (O·RING & GLYCERIN)

,I

5 34458 CAM 1

'6

49171

WEAR

PLATE

1

7

302575

DOWEL 8 48253 SPRING SEAL WASHER 1 9 34463

IMPELLER COVER SCREW ' 6

10 48359 IMPELLER

COVER

O-RING

'1

'

11

33041

O-RING 1

12

33037 CAM WASHER 1,

~,

13 46662 CAM SCREW

l'

:e

14 ' 48254 ' SPRING SEAL 1 15 49169

LIP

SEAL

l'

==

16' 34464, BALL BEARING

'2

:t:!

17

33045

RETAINING

INTERNAL

RING

l'

;;I

18

33044,

RETAINING

EXTERNAL RING

l'

:a

49000

PUMP

REPAIR

KIT 1 i

37431

PUMP

KIT (MOUNTING GASKET & FITTINGS)

,I'

~

WHEN

ASSEMBLING:

APPLY A THIN

COAT.QF

GLYCERIN

TO

THE

(NSJOE

OF

THE

COVER.'

THIi

-COVER

O-RlN6,ANO

THE

IMPELLER

'

Engines & Generators

:s:

."

,-

-u

Z

~

00

a

00

a

--

Zinc

Anode

A

zinc circuit zinc

anode

place in

effects

The

condition

and

the

should

NEW

anode,

within

the

is

to

the

raw

of

electrolysis

anode

be

carried

#011885

or

pencil,

heat

sacrifice

water

of

the

cleaned

on

REPLACE

ZINC

is

located

exchanger.

them

cooling

on

other

zinc

anode

or

replaced

board.

ANODES

in

the

raw

The

purpose

to

electrolysis

circuit,

thereby

components

shonld

be

as

required:

REPLACE

.

COOLING

water

cooling

of

having

action

takjng

reducing

of

the

system.

checked

CLEAN REUSE

monthly

Spare

AND

SYSTEM

the

.

the

anodes

.

If

the

zinc

which

the

erung

the

boss.

frompossibly removing poor

condition,

the

exchanger.

clean

the

exchanger

aged

when.

to

your

engIne

ber),

O-ring

NOTE:

The

do

.not

require insulate ing

preventing

Heat

Exchanger

After

approximately

and

pressure

motive

radiator

exchanger.).

anodes

need

zinc

anode

is

anode

with

another

tearing

the

iinc,

note

thOte

are

Remove

inside

of

all

zinc

end

gasket

in

~emoving

and

threads

the

zinc

~e

model

cover,

of

sealant.

from

s heat

the

Sealant

the

electrolysis

Service

1000

test

the

engine's

shop

should

replacement,

threaded

the

probably a lot

the

case

and

with a wrench

wrench.

off

the

exchanger

condition

end

of

debris.

Always

the

present

end

cover.

exchanger

install a new

zinc

anodes

the

shoultlnot

metal

of

the

action

on

hOl/rs

of

~eat

exchanger.

be

able

hold

the

hex

boss

while

1his of

it.

of

zinc

heat

have a spare

one

Replace

end

zinc

lire

pipe

be

prevents· If exchanger

gasket

shell.

After '

the

zinc

flakes

becomes

the

gasket

part

anode.

threads

used

as

the

heat exchanger

the,

zinc.

opera~on,

to

clean

remove,

(A

and

.,

local test

into

loos~

hex

is

in

within

and

heat

dam-

(refer

num-

and

it

may

hous-

clean

auto-

the

heat

NOTE:

Electrolysis

installation

and.

action is

vessel

location;

COVER

SECURING

BOLT

the

result

not that

INSPECT BOTH

ENDS

of

each

of

the

CLEAN

particular

engine.

HEAT

OUT

DEBRis

.

NOTE:

Operating

that a

heat

every

1000

EXCHANGER

OUT

EVERY

100

HOURS

TYPICAL

ASSEMBLY

'DRAIN

in

siliy

exchanger

hours.

and/or

tropical

cleaning

~

.~=.

ANTIFREEZE

CO'OlANT DRAIN'

(PftCOCK

~

be

IRBlEED

PETCOCK

OR

waters

performed'

HEX

PLUI1;'

may

more

require

often

than

NOTE:

When

sure

that installed. elld

plate

installing

the

end. Failure failure/sea

Engilles & Gellerators

the

cover

seeUling,bolt.'s

to

install

water

heat

miiiealingO.ring

leakage.

19

exchanger

sealing

end.

covers.

O-ring

can

result

Be

is

in

ENGINE

TYPI.CAL

LUBRICATION

OIL

PRESSURE'

OIL

PRESSURE

SWITCH

OIL

FILTER,...---

OIL

PRESS~RE'-.....fi~~

RELIEF

OIL

-~41

VALVE.'

OIL

DRA.IN-~"-'

.O!A_GRAM

.

LUBRICATING

2.

SCREEN

Replacing

filter;

you

• in the

"il

from

to

lessen

should

NOTE:

filter

to

Place filter

when (Oil or cooling

old

oil

sealing

rupber block,

OIL

the

Oil

may

find

upper

and

lower

it

into

a container

spillage. A small

be

helpfijl

in

Do

not

punch

make

certain

some

paper

unscrewing it

any

other

fluid

ability.

Please

filter

as.

it

is

gasket

carne

sealing

gasket

g~ntly

remove

Filter.

it

helpful

portion

removing

this

it

can

towels

on

keep

removed

off

remains it.

When

removing

and

cleaner

of

the

old

before

removing

style

automotive

the

old

oil

hole

without first loosening

be

removed!

and a plastic·

to

catch

the

engine

your

to

with

the

.

any

engine

make

old

sealed

bag oil left in

reduces the

sure

oil

filter.

against

the used

to

filter to

filter.

aro~nd

clean.) Inspect

that

punch a

~ain

it.

This

filter

wrench

•

the

engine's

the

If

this

the

engine

oil

hole

helps

the

filter.

rubber

the

ENGINE

1.

TO

DRAIN

OIL

UP

THRU

REMOVE

USINGAN~~r:::::~:::)~'i!~;~ge

A

contaminants. and

OIL

Draining the

the

sump

drain

while

the

engine

replace

the hose

securely.

NOTE:

Thread

is

114NPT.

THE

OIL

OR

PUMP

THE

HOSE.

WARNING:

nails

thoroughly discard used

Clothing

oil

properly.

CHANGE

Oil

Sump.

hose

(attached

is

warm.

in

its

bracket,

size

for

the

.

Used

engll1fl

Avoid

prolonged using

or

rags

containing

Discharge

to

the

Drain

the

and

lube

oil

011

contains

skin

soap

and

the

used

oil

front

of

used

oil

complerely,

replace

drain

.

FOR

the

hose

EX1ENSION

NPT

harmful

contact.

water.

LI/under

used

oil.

through

the

engine)

end'cap

capped

Clean

skin

or

Discard

end

OIL

#036918

When

installing

gasket's sealing

apply a thin on

the

filter

nipple,

NOTE:

material generic parts

parts.

Immediately

run

the

that

there

3. Filling

cap

on engine pressure.

oil

filter

Theu

check

Fill

to,

the

engine

FILTER

the

surface

coat of

new

oil

filter.

and

then

Generic

filters

standards

might

engine

to

make

are

no

oil

the

Oil Sump.

the

top

of the

for a few

or

but

moments

Make

sure

from

the

quantity'

not

over

require additional

new

oil

on

the

clean

engine

Screw

the

tighten

are

not

or

diameters

be

entirely

after

an

suit!

leaks

around

, ,

Add

new

engine.

while there is oil

drain

of oil

the

high

filter

element,

engine

block

oil

to

the

filter

onto

the

filter

finnly

recommended,

of

important

differentfram

ailfilter change

the

oil

pressure

the

new oil

oil

through

After

refilling,

checking

no

leakage

system,

with

mark

oil.

the

on

around

and

lube

the

stop

dipstick,

wipe

the

filter

free

of

oil

and

rubber gasket'

threaded by

as

items

genuine

andailfil~

is

filter.

the run

the

oil

hand.

the·

on

normal

oil

filler

the the

new

the

engine.

dipstick.

should

oil

.

and

.

Englnes,,& (lenerators

20

INSTALLATION

This

popular

ter

from

engine

NOTE:

instructions

To

install, WESTERBEKE's install

Contact

accessory

the

engine

room

bulkhead.

Refer

to

ENGINE

on

simply

this

kit

with

your

WESTERBEKE

to a more

removing

remove

remote

the

·is

used

to

reloc~te

convenient location

.

OIL

CHANGE

the

oil

jilter.

the

engine

oil

filter

oil

filter

facing

dealer

REMOTE

the

in

this

oil

filter

kit

as

shown.

down

as

for

more infonnation.

OIL

.

engine's

such

manual

and

thread

Always

illustrated.

PN#

oil

as

for

FILTER

040078

NOTE:

filan

on

incorrect

A

correctly. bY1lass. from

failure.

imediatelyand

(OPTIONAL)

.

Westerbeke

installation

CAUTION:

reaching

'If

If

the

valve

there

is

not

It

oil

In

the

engine

is

no

check

of

Is

flows

responsiblefor

the

Remote

vital

to

install

in

the

filter

assembly

causing

oil

pressure

the

hose

engine

failure

ail

Filter.

.,

the

oillin~s

reverse

direction,

Will

prevent

an

internal

reading,

shutdown

cnnnections.

due

the

engine

to

oil

THE

OUT

CONNECTION

MUST

ATTACH

OIL

FILTER.

TO

ATTHE

CONNECTION REMOTE

APPLY A THIN

INSTALLING

TIGHTEN

CONTACTS

THE

COAT

OF

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

CLEAN

OIL

THREAD

THE

3/4

TURN

~

__

'"

TO

THE

O·RING

KIT

AFTER

WHEN

ON,

THEN

HAND

THE

O·RING

FASTEN

SECURELY,IO

(SCREWS

ARE

THE

IN

CONNECTION

MUST

ATTACH

iiCiO~MNNioEii'ECTI.DiOiN

HOSE

TO

THE

AT

THE

FILTER.

OUT

A

B~~:~IT:~1

OWNER

iii

"

APPLY, A THIN

,

GASKET

WHEN

,

toNTACTS

COAT

INSTALLING.

THE

OF

BASE,

CLEAN

OIL

AFTER

TIGHTEN

IT

TO

niE

FILTER

THE

FILTER

AN

ADDITIONAL

, Engines & Generators

21

DOMESTIC

HOT

WATER

TANK

CONNECTIONS

DESCRIPTION

Bothihe connections [fthe owner/operator the bypass the instructions presented

INSTALLATION

The heater high

connecting reasonably direct line

two

•

CURRENT

SIMPLY

CUT

AND

INSERT

OF

HOSE.

END

OF

THE

MATTER

WHICH

or

low

mid

three cylinder

to

send

engine

wishes

hose

and connect a water heater

MODEt.ENGINES'

INTO

THE

TWO

COUPLE

CONNECTORS

EXISTING

CONNECTORS

THE

HOSES

AND

RUN

.

should

be

mounted

position

hoses

in

from

relation

the

without

models

are equipped

with

coolant to a domestic water heater.

to

connect a water heater, remove

as

described in

below.

'

HOSE (PifRr

FROM

TIGHTEN

TO

AND

.

AT

THe

THERMOSTAT

#802391

THE FROM

)"INto

WATER

TANK

THE

HOSE

THE

TANK.

CONNECTOR

HOUSING

THE

TWO

TO

THE

CLAMPS.

IT

PIECES

OTHER

WILL

conveniently either in a

to

the

heater

any

engine, so

to

the

loops

engine

which

·that

can

run

might

the

in a

trap

NOT

air.

THE

BY-PASS

HOSE'

With

the

points

A and B

These

connections

heater

at

water.

, Connection

connect heater

while

connection Hoses

should heater to the from

the

heater,

higher

fitring

system.

MODEL

,

bypass

all

times

point A on

to

the

B,

engine

heater

then

on

Avoid

(CONT.)

ENGINES

hose

re11]?ved,

for

hoses

to

assure

but

do

not

the

lower

of

the

upper

connection

nearest

the

rise

continuously

so

that

to

the

engine.

an

air

bleed

the

heater

loops

in

the

HEATER ABOVE

,HEATER

,

there

remain

run

to

and

from the water

'"

fiowofhot water through

restrict

the

Flow

Control

two

connections

on

the

heat

exchanger_

from

their low

trapped

for hose

If

trapped

petcock

bleeding

runs

air

must be installed at

which

BELOW

HEATER

COILS PRESSURE MANIFOLD

two

engine's cooling

housing

on

the

heater

point

will rise

naturally

air is able

air while

will

THE

ENGINE

BELOW

CAP

ON

ENGINE

connecting

heater.

the

should

water

returns

to

at

the

to

rise

to

the

filling

llie

trap

air.

ENGINE ,

-

engines & Generators

22

HOT

WATER

If

any

portion

own

pressure expansion highest

24177. at

the

heater

the

retum.

to

the

tanks location

control. Install location level

can

now

serve coolant tank kit is

The

pressure installed coolant.

taDk

once

good

coolant the engine's coolant not

at

the

The

hose expansion tank continuously

the

system

cap,

tank

point.

The

Tee

the

connection,

Tee

such

as

easily be

as a check

recovery

installed,

cap

once

Finish

the

circulation.

engine

connection

from

to

HEATER

of

the

must

remote

right

the

in a

tank

on

the

filling

system

manifold

should

rise.

DOMESTIC

ABOVE

heating

circuit

the a pressurized

be

installed

remote

expansion

choosing

at

the

and

remote

sail

locker

checked.

and

is

not

since

the

engine's

the

is

filled

should

from

be

the

heater

the

in

expansion

heater

and

other

expansion

so

The

remote

system

used

this

tank

manifold

cooling

and

During

engine

be

done

cap. the

heater

routed

and

to

the

THE

ENGINE

rises

above

(aluruinum)

the

circuit

tanks part

tank

into

the

higher

plumb

back

to

tank

the

fresh

expansion

fill

point.

when

the

serves

system

from

is

free of

operation,

at

the

to

the remote

supported

tank,

enabling

HOT

the

engine's

remote

to

become

number

the

heater

of

the

two

a single

the

engine's

in

a convenient

water coolant

ian!<:

The

plastic

remote

the

should

is

remote

same

filled

air

the

and

so

be

with

remote

tank

as

any

expansion

function.

eXhibits

checking

WATER

PRESSURE LOWER

the

is

circuit

.

for

line

up

flow

will

and

to

rise

air

in

.

TANK

THAN

REMOVE

CONNECTIONS

CAP

IS

RATED

MANIFOLD.

THE

..

CAP

BY-PASS

~.

~

..

,

ENGINE

HEAT

HEATER

HOSE

COILS

PHt:>OUlit

ABOVE

CAP

ON

ENGINE

HEATER

MANIFOLD

ABOVE

ENGINE

.....

. Englnes.&

23

Generators

TACHOMETER/HOUR

The

tachometerlhour meter ment panels common other volts on

the

The

tachometer circuit operates

from

tachometer input

the

alternator

volts

The following

fault

a

meter.

Hour

Check

tenninals.

1.

Voltage

2.

Voltage nections terminal

Tachometer

Check

terminal

1.

Voltage

tion

2.

AC output

3.

Check for ground.

4.

Check electrical connections

minal

Tachometer

1.

Check terminal

2.

Check for terminal

3.

Check that alternator alternator

contains

ground.

the

tachometer.

alternator

back of

~ne

DC.

in

meter

for the

charging

the

of

the

diodes

producing

are

either of

Inoperative

proper

present - meter

not

present - trace (+)

for

fault.

to

verify

Inoperative

for

the proper

and

(-)

terminal

present - attempt adjusting meter through calibra-

access

hole.

voltage

not

voltage.

AC

to

alternator

Sticking

for

proper

and

(-)

good

and

alternator.

pivot

METER

used

two

separate electrical circuits

One

circuit operates

The

hour meter circuit operates

voltage supplied to the (+)

instrument.

in

the

alternator

terminal

procedures the

voltage at tach terminal on alternator

while

battery charging voltage

to

two

circuits

DC

voltage between (+) and

is

defective - repair or replace.

(Jump

12

the

operation.)

AC

voltage between tachometer input

with

the

No

results,

present - check

connection.

AC

voltage

terminal. ground

connection between meter

is

well

bolt.

in

propulsion engine

the

hour meter

on

AC

voltage

the

engine

follow

in

a tachometerlhour

and

(-)

volts

DC

engine mnning.

repair

or

for

proper alternator

from

tachometer input

between "tach inp."

grounded

6-8

and

supplied

is

mnning,

when

troubleshooting

e1ectlical to meter (+)

replace

to

engine block at

TACHOMETER

NOTE:

instru-

with

and on

12

terminal

volts,

fed

to

the

and

13.0-14.8

(-)

con-

meter.

DC

to

ter-

(-)

a

the

Current

dial

to

set

calibrating

COARSE ADJUSTMENT

TACHOMETER

NOTE:

In a new

the

tachometer engine's installations.

1.

Warm

Remove

cloth

pulley

2.

Start

3.

Aim

confirm

tachometer reading. Adjust

using

instrument reading

is

showing.

bring

4.

Set has speed

model

the

tachometer

screw

rpm.

This

up

the

any

and

place a piece of suitable reflecting tape

to

facilitate

and

idle

the

light of

the

instmment coarse adjustment

the

instrument

the

tachometer

been

factory

screws

tachometers

is

then

usedior

CHECK

installation

may

not

always

calibration

engine

to

specks

on

use

the

engine.

the

tachometer

engine

speed.

to

Then

use

to

adjusted

have

been locked

use a coarse

to

the

crankshaft

fine

(New

Installation)

having

be

should

normal the

crankshaft

of a photoelectric

Check the instrument panel

the

closest

the

fine

calibration adjustment

to

the

exact

the

idle

speed

and

the

~

~~

I

pulley

tuning.

new

instrument panels,

correctly

operating temperature.

onto

tachometer

in

be

checked

pulley

the

to

R.P.M.

rt:ading

(the

idle

screws

place).

calibrated

type

reflecting tape

calibrate the

that the photo

as

engine idle

,

adjustment'

rpms.

The

to

in all

new

with a

clean

on

the

tachometer.

in

the panel

to

the

photo

speed

and

high

-

the

to

by

tach

tach,

Tachometer

ca"

With a hand-held tach on pulley retaining nut or with a strobe-type tach,

front crankshaft pulley rpm at idle.

b. Adjust the tachometer using a

through the the the (Verify

tachometer

Inaccurate

CAL.

(calibration) access hole in tachometer. Zero rpm indicated by

the rpm

as

needed)

at

idle

the

frollt of the crankshaft

5/64

or 2mm Allen wrench

the

tachometer

the

strobe or hand tachometer.

and

high rpm and adjust

arid

read

the

rear of

then adjust it

the

to

Engines &

24

~mR

.3.-.-

11DRlO

"

~

•

-

II.

9l~ID

~

, '

, . ,

"

'I

i

I

-

----~-

OIL

P~15S,

~

;<t-.

t

~

I.

K[T

~G~UG[

,,,,,,;~~

III

Btl <

.!!!...lli.@

~

0:

",\

''"

SWITt~

VDllM[l[~

--------------------------

Generators

(US

------

, ,

-i!:l

~'"O

~

>OS

'Q7

IUR[D

II.

~

D ®

I

~

-

"

" "

I!

ALTERNATORS-

TESTINGJTROUBLESHOOTING

#10

ORANGE

BB!"

TO

STARTER

m

PINKJBLUE'

TO R TERMINAL-

:~

81

DESCRIPTION

The

following

that

are

supplied

Generators.

ELECTRICAL

The

charging regulator, circuit breaker

of regulator back of

It

is voltage loads provide charging

electrical

the

use

desirable

regulator)

that

the

an

of integrated

is

are a permanent

system

system.

ALTERNATOR.

The stator rectifier converts battery

Power alternator

package

These

rated rpm at alternators range

package

the

charging

to

the

is

contained in

alternators

output

an

ambient

of

_40°

TYPICAL

50

ALTERNATOR

"'...,.,.."'''

information

with

WESTERBEKE'S

CHARGING

system

consists

engine

DC

wiring

and a battery

circuits

very

compact

alternator.

to

test

the

charging

using

the

technician

as

well

with

as

DESCRIPTION

is

connected

AC

regulator

provided

is

achieved

are

designed

to

to a three-phase,

which

contains generated and

accessories,

and by the

produce a rated

at

temperatnre

to

212°P

(-40°

AMP

g~~~I8

.

MANUALFOR

.

WIRING

applies

to

the

CIRCUIT

of

an

alternator

hamess, a mouuted

with

connecting

(IC's),

and

is

mounted

system

wiring

hamess

part of

the

an

operational

the

major

components of

six

diodes.

in

the

stator

the

field

of

the

field

diode

alternator.

output of 50 or

approxiroately

of 75°P

operate

in

to

100°C).

'~..j;EiiiniNi\L

,

Tff~::'NG

ALL

CONNECTIONS

standard

Engines_

the

electronic

internally

(alternator

system

full-wave

to a DC

the

(or

(23.S°C).

an

ambient

alternators' and

with a voltage

DC

cables.

and

electrical

and

will

test of

the

bridge

The

bridge

output

integral

6000

diode

alternator

regulator

trio)

51 The

temperatnre

Because

voltage

or

on

the

and

then

the

for

amps.

VOLTAGE

The

device the

.

system The

.

thick~film

adjusted encapsulated

possible

ALTERNATOR

Use exists determined have a qualified

A

altemator altemator

LOW

If

the

of

faulty

problem.

REGULATOR

integra!

voltage

regulator

voltage

which

applied

voltage.

assembly

to

the

damage

senses

design

proper

to

protect

TROUBLESHOOTING

this

troubleshooting

with

the

charging

that

the

WARNING:

can

until

BATTERY/FAULTY

starter

only

spinning

the

engine

connection in

PRELIMINARY

Before

starting

testing

the

1.

Make

2.

Check

if

it

is

3.

Check

and

tight. resistance undercharging corroded battery reaching a fully

4.

Check A low readings

NOTE:

An selector the

batteries

with

the

starting

OK

and

following

certain

the

drive

worn

that

all

Loose

and

the

condition of

or

discharged

in

the

isolator

switch

so

house

battery

the

problem

the

or

regulator

the

to

the

utilizes

techniques.

due

to

alternateir

technician

A

working

become

If

has

is

system

field

all-silicon

regulating

the

circuit

handling

section

circuit

or

check

alternator

very

cooled.

an

electronic

voltage

in

order

After

valve,

and

or

to

determine

or

with

voltage

it.

hot.

00

vibration.

CIRCUIT

moans

or

makes a clicking

to

life

it

is

likely

the

starting

circuit

INSPECTION

actnal

alternator

checks

your

alternator

belts

for

glazed.

tennlnals,

or

corroded

this

conld

or

damage

cables

could

charged

the

battery

tests.

with a diode, a solenoid,

is

usually

mounted

the

starling

batteries.

but

not

is

If

the in

the

and

are

recommended.

is

securely

proper

tension.

connectors

connections

cause

overcharging,

to

the

charging

prevent

condition.

battery

may

in

battery

the

isolator

house

battery,

battery

switching

level and switches

to

maintain

semi

the

voltage has

the

entire circuit is

the

components

the

alternator.

regulator is

run~

not

touch

a low battery or a

and

voltage.regulator,

and

the

and

charge

cause

it

conductors

if

a problem

hot. A failed

the

sound

not

an

alternator

mounted.

Replace

plugs

are

cause

high

system. battery

if

false

or

misleading

or a battery

the

circuit

to

is

not

discharged

is

charging

the

alternator

charging

circuit.

proper

and

been

from

If

it is

faulty,

instead

•

the

belt

clean

Badly

from

necessary.

isolate

along

the

is

..

Engines & Generators

25

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

A

certain away

1. Start the engine.

2.

3.

4.

S.

6.

THE

ALTERNATOR

CAUTION:

that

from

After

the starting multimeter

a.

If

the altemator directly

b.

If

the exists continue

Thrn 00' the

Ensure connections

If

a battery selector

ensure

that it

Thrn on the ignition switch,

engine. . Check

the battery

condition,

everyone

sheaves

engine

battery

set

voltage

is

to

"Checking

voltage

with

either

with

·engine.

that

the

are

is

the

Before

and

has

voltage

on

DC

is

increasing

working;

remains

Steps 3 through

battery

tight

on

the

voltage.

reading

;--:-,-/~q

starting

Is

clear

of

belts

during

run

for a few

at

the

volts.

toward

omit

the

Service

around

the

altemator or

Inspect all

terminals

and

clean.

switch

is in the

correct

If

the

should be 12

the

engine

make

moving

battery tenninals

Steps 3 through 8 and

setting.

but

parts!

test

procedures.

minutes,

14

volts,

Battery."

12

volts,

a problem

the

charging

8.

wiring

and

the.

engine

charging

do not

start

battery

is

to

13

volts.

.

MEASURING

•

BAITelIY

ENGINE

Keep

measure

using

the

circuit;

connections.

ground

circuit,

the

in

good

VOLTAGE

RUNNING

the

a

go

'li~~~~

6

TESTING

1.

2.

3.

4.

S.

THE

OUTPUT

Connect connect the negative

Wiggle

vol!I)leter.

. battery voltage,

obtained, or output circuit damaged

Start the engine.

Repeat the ground, The voltage reading shouidbe between volts. it repaired

If

terminal B, use terminal. inspect the Jump battery) and operate

is

the positive probe

the

engine

The

meter

if

the

for

wiring.

same

the positive probe

If

your altemator

at

a reliable service shop.

the

previous test reads

If

12 volts is not present

wiriIlg

12

volts

from

13-14

volts, . then

TESTING CIRCUIT

THE

ENGINE

wiring

and

should not

reading varies, check

loose or dirty connections

measurelhent,

the

meter

for breaks and poor connections.

a

OUTPUT

RUNNING

.",...~

CIRCUIT

to

probe

to

harness while observing

should indicate the

to B with

is

over or under-charging,

ani)'

to

measure the

12

volt source (such

the

alternator.

the

alternator

,MEASURiNG

..

BATIERY

'(lGN.ITION

the

output terminal Band

ground

..

appro~imate

vary.

If

no

reading is

the

alternator or

the

negative probe

the engine

13.5

and

battery voltage at

DC

excitation

at

exciter terminal

is:

the

If

the

voltage'

is

OK

.

VOLTAGE

ON

the

to

running:

14.5 have

R,

..

output

,.y'

.WESTERBEKE

Engi,;e~

26

& Generators

EXCITER

'TERMINAL

"R

(+)

'~,\

.

ALTERNATORS

TESTING/TROUBLESHOOTING

TESTING

1. Connect

2.

TESTING

THE

excit~tion

(-) lead

Turn the battery switch to the the multimeter reading.

2.5

volts

THE

EXCiTATION

J~IRCUJT

(IGNITION

UIVl'-~il

3.

If

the reading is hetween

rotor

field

4.

If

the reading

field

circuit probably

5.

If

no reading is obtained,

alternator-excitation lead

the regulator. Disconnect

Connect the'positive multimeter probe lead

and

If

the

multimeter voltage, the voltage regulator is defective replaced. If excitation circuit for damaged

EXCITATION

the

positive (+) multimeter probe

terminal R

to

ground.

(see

illustration).

circuit probably

is

between

the negative multimeter probe to ground.

now

no

voltageJs indicated, check the

wiring.

CIRCUIT

on

the

alternator

The

reading should be

.75

is

shorted

6.0

is

open.

an

or

in the excitation circuit of

the

lead

indicates

loose

or

dirty connectlons or.

and

on

position

and

1.1

or

and 7.0 volts, the rotor

open

eXists

from

an

approximate battery

to

the

the negative

and

volts,

the

wpunded.

in

the

exe.

terminal

to

the

excitation

and

note

1.3

.

must

to

R.

be

CHECKING

Check have running. charging circuit isolator,

When

.

is

back terminal wiring

ALTERNATOR

If

tests sembled do

the

NIiTE:

instructions

staridard

·

BATTERY

The

·

the

engine's

Cranking

·

Review establish engine's starting batteries

•

Mouitor

•

•.

•

THE

SERVICE

the

voltage

.voltage between

If

circuit.

·by

checking

battery

the

problem

in

operation,

studs.

harness.

of the

not,

there

Troubleshoot.the

switch,

Also

REPAIR

indicate a

and

job.

WESTERBEKE'S

alternators.

failed

repaired.

for

the

CARE

minimum

engine Check

hydrometer.

Use level.

Make tight

Keep

recommended

12

volt

Amps

(CCA).

the

manufacturer's

a systematic

your voltmeter for

operation.

the

electrolyte

ouly

distilled water

certain that

to

the

battery

your batteries

service

13

and

is a

pro.b1em

the

wiring

and

the

has

been

solved

take

the

clean

the

alternator,

Any

good

service

disa"sembly

DC

control

recommendations

maintenance

and

level

battery

posts

clean

BATTERY

battery.

14

and

battery

time

connecting

capacity

house

and

to

bring

cable

(and

and

lhis

volts

when

in

the

service

battery

connections,

itself.

and

before

to

tighten·

terminals

it

will

need

alternator

Manual

and

circuit

proper

has

repair

of

is

schedule

batteries.

charging

specific

electrolytes

connections

to

your

free

of

battery

and

service

of

the

600

engine).

corrosion.

the

engine

battery

eharging

the

alternator

clean

to

be

detailed

their

battery

- 900

lind

for·yout

during

gravity

to a proper

are

shOuld

is

solenoid,

the

from

the

disas-

shop

can

used

C;old

thel).

with

a

clean

in

and

(+)

.

TERMINAL

R

TESTING EXCITATION

THE

CIRCUIT

(IGNITION

ON)

~

WESTERBEICE

Engines & Generators

27

A

CAUTION:

that

everyone

sheaves

A

charging switch

and

CAUTION:

circuit,

when

Before

is

clear

belts

the

of

during

To

avoid

never

engine

starting

moving

test

procedures.

damage

shut

off

Is

running!

the

engine

parts!

to

the

engine

make

Keep

away

battery

certain

from

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are When should

PREHEAT

"click"

on

is

and

INSPECTION

To

inspect

the

plug, remove the

tions,

then

unscrew head. soft oil

deposits.

burn

Thoroughly

brush

and

erosion;

cleaning

While

if it

has

clean

TESTING

An

accurate

Touch

the other

glow method

You

can

(8

to 9 amps

A

to

the

testing

way

to

one

prod

to

the

to

the body of the

plug

will. have a

can

be

used

also

use

an

per

plug).

WARNING:

touc".

Be

carefurnot

the

plugs

wired

pressed

the

or

unclamp

each

solution

cleaning,

eroded

test

glow

1.0.-

with

the

ammeter

These

plOW

through glow

the

preheat

at

the

control

plug

should

electrical

each

plug

plug's

tip

and

to

remove

examine

too

plugs

plug's

glow

to

1.5-ohm

plug

to

til

the

m\lch,

is

with

wire

plug,

as resistance.

in

or

test

the

plugs

will

bum,yourJingers

.,

solenoid.

panel

this

begin

terminal

from

the

tlrreads

all

the

tip

for

wear

replace

the

an

ohmmeter.

connection,

shown.

out of

the

power

drain

become

.

'.

solenoid

to

get

connec-

cylinder

with a

carbon

and

plug.

and

A good

This

.engine.

very When

.

hot.

and

hot

Re-install plugs 25 short circuit. compound

Glow

A

than

the

should get

seconds.

Plug

Tightening

WARNING:

30

seconds

plugs

in

very

If

the

plugs

When

reinstalling

on

the

tlrreads.

Torque 7 -11

00

Tightening

(1.0 -1.5 m-kg

the

engine

hot

(at

the

don't heat

not

keep a glow

TERMINAL

tOl'flue:

THE

and

test

them

terminal

the

Ib-ff

up

quiCkly,

glow

(1.0

end)

plugs,

-1.5

plug

.....

____

(7·

IIft-lb)

GLOW

PLUG

OHMMETER

again.

within

check

use

kg-m)

on

for

TEST

The

20.

to

for

a

anti-seize

,

more

GLOW

PLUG

...>'..-l-~~

Engines & Generators .

28

DESCRIPTION

The

starter

is

a new

type,

small,

high-speed internal-reduction

separate pinion shaft exposed smoothly without motor shaft

lever are identical

from

the

shaft.

A rednction

and

a pinion

outside the

is

supported

mechanism,

to

conventional

motor

shaft;

gear

shaft.

The

starter

becoming

at

switch

and

so

both

STARTER

light-weight and is called a

starter.

The pinion shafris

the

pinion

~lides

only

is

installed

pinion sliding part

that

fouled

ends

overrunning

ones.

between

the

pinion

with

dust

on

ball bearings. The

clutch

the

is

not

may

slide

and

grease. The

inner circuit

on

motor

the

MOTOR

IGNITION TERMINAL

[r~---(M)

TERMINAL

TERMINALS-""-~

MOTOR

TYPICAL

STARTER

REFER

DIAGRAM

MOTOR

TO

THEW/RING

IN

THIS

...

,.,..

,

MANUAL

TROUBLESHOOTING

A

WARNING:

procedures

Sparks

could

Prior

to

testing, make

charge

and

that the

(terminals)

the

'ground

To

check seconds, hand that indicate resistance,

Using

terminal (ground).,

If

you

are clean

wire

the

never more

along

the wires

a multimeter,

stud

read 12 volts, the starter is faulty.

The

must

not

cause

certain

starting

and

connections

wiring, try

than

and

test

on

the start

following

be

used

an

explosion

the

system wiring connections

tight.

on

Cfl",c'dng

10

,seconds

terminals

Repair

the

voltage between

solenoid

...

emergency

with

ships

Pay particular attention

the engine

the starter for a

or

replace

SOLENOID

starting

gasoline

and

batteries

at a time,

looking for warm

and the

fire.

block.

any

engine

engines.

are

few

then

trouble

the

positive

block

at full

run

to

your spots spots,

To

test

the

ignition circuit,

is

one

of

the

small terminal

Use

circuit). from that ignition terminal

terminal

If

the starter cranks, the fault

circult.

If

the solenoid clicks bnt nothing happens, the starter

motor is probably faulty.

a screwdriver, don't

on

the solenoid.

'

locate

the

ignition(s) terminal (it

studs

and

is wired

touch

the

blade,

to

the

positive battery connection

lies

with

the

ignition

to

the

to

~

SOLENOID

IGNITION

,

TERMINAL

If

nothing hapF"ns

cnrrent

wiring defective,

..

Check the battery

connections.

'AI''h'"--_(+)

.

r~--(M)

at

all, the solenoid is not getting

it

isolation

is

also

possible that the solenoid is

.

switch

'TERMINAL

~

and

inspect the

ignition

jump

POSITiVE

TERMINAL

-..v

WESTERBEKE

Engines & Generators

29

A

WARNING:

fly.

when

jumping

space

Is

free

gasoline,

and

materials

of

tirat

stored

There

will

terminals.

potentially

there

are

nearby.

be

arching

Be

certain

BJi#lloslve

NO

fumes,

flammable

and

the

sparks

will

engine

especially

solvents

or

STARTER

MOTOR

, A

WARNING:

position

the

other

IGNITION TERMINAL

Test screwdriver blade screwdriver blade would

yourself

engine

in

crew

members

again

by

jumping the two large terminal

cause a short.

When

performIng

safely

away

case

the

engine

of

the

~Ii{}_;:----(M)

firmly

between the studs.

to

touch the solenoid or starter casing, this

from

starts-up.

danger.

these

procedures,

the

moving

Also

studs,

Do

warn

not

parts

of

TERMINAL

Hold the

allow

the

EMERGENCY

Corrosion can cause the spcradic problem of time bul'not will

Iieed

It

is however, sometimes possible

starter ligbtly with a small

With the battery switch off and

starter/solenoid casing

CAREFULLY FITTINGS

OR

START

to

the starter brushes and/or

another.

to be rebuilt. '

NOT

WIRE

\

If

corrosion

as

shown,

TO

HIT

~

CONNECTIONS

hammer.

~"

the

solenoid contacts

the

engine starting one

is

the problem, the starter

to

get

started by taping the

no

ignition,. tap lightly

then

try

to

start the engine.

TAP

LIGHTLY

\

.

INDICATED

on

the

WHERE

A

WARNING:

starting the

If

the starter spins, the solenoid

If

the starter fails to spin, the motor

If

no arching occurred, tbere is no jnice reaching the

solenoid.

NOTE:

In that engages using will stalter switch on

it will create enough magneticfieldfor the

though

current

screwdriver.

Sta1ter

the

pre-engaged model,

a screwdriver

run

the

contacts inside

There

will

be

arching

should

be

flowing

motors are either inertia type or

the

starter motor

to

bypass the solenoid

nwtor wiihout engaging the

to

provide power

the

thru

is

faulty.

is

probably faulty.

solenoid also moves an arm

to

the

flywheel

flywheel..

to

the solenoid. Hopefully

solenoid are

as

the

full

the

blade

pre~engaged.

of

the engine.

on

such

ann

to

bad.

of

11.

starter

Thm

the

nwve even

If

that fails, tum the battery switch

member tum

with

the

contact to start the starter will need to be repaired.

the

barrimer.,

the

ignition on and off rapidly as you

This may loosen the brushes and allow

engine. When

on

and

have a crew

you

reach a repair facility,

tap

SERVICE

WESTERBEKE uses a standard starter motor which can be serviced or rebuilt at any starter motor automotive service center,

If

replacing the st8rtef

certified

USCG standards.

dealer.

TO

1. Disconnect the negative battery

2.

3. Label and disconnect the wiring from the

- 4. Remove the starter mounting bolts.

5. Remove

for marine

REMOVE

If

'necessary,

. to the starter

allow

wires

the

starter will have to be turned

obstructions,

motor,

make certain

use.

Automotive starters

If

in doubt, contact your WESTERBEKE

FOR

SERVICE

remove any components

motor.

to

touch, tape over the terminals).

starter from the

engine.

to

the

new motor is

do

not meet

cable.

to

gain

starter.

In

some

a different angle to clear

full

cases

access

(Do not

again

the

~

WESTERBEKE

Engines & Generators

30

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Engines. & Generators

33

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(#36467)

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Enaines & Generato'rs

34

The

following relating lems,

NOTE:

troubleshooting

to

engine

service,

and

the

recommendations

Fuel

run/shut off solenoid (Optional).

the

probable

table

describes

to

overcome

ENGINE

certain

causes

of

these

TROUBLESHOOTING

problems

these

prob-

problems,

NOTE:

The

ampere

the

back

the

same

engine's

manual

of

the

bracket.

electrical

reset

engille.

circuit

The

system

breaker

preheat

is

protected

located

solelloid

by a

20 all a bracket is

niounted

at

on.

No

pan,1

indications;

or

fuel

pump

is

on

and

START

button

engagement.

START

button

indications

fuel

solenoid

Engine

cranks,

start.

fuel

Engine

can't

Battery

runs

-

Battel)l

Problem

fu,lsol,nold

Is

not

working

PREHEAT

not

is

depressed,

.

15

depressed;

OK;

starter

n~t

functioning.

but

solenoid

be

stopped.

down.

charging

button

does

energized.

(key

Is

depressed).

no

panel

solenoid

not

switch

starter

OK;

1.

Battel)l

2.

20-amp

1

O-amp

3.

preheat

4.

loose

5.

Preheat

1.

Connection Gear

2.

Faulty

3.

Faulty

4.

5.

loose low

6.

1.

Poor

2.

Defective

1.

Faulty

Preheat

2.

Low

3.

Faulty

1.

2.

Dlsconn.ct

3.

Fuel

Oil

1.

High

2.

Low

3.

Poor

4.

DC

5.

(tachometer

DC

1.

Alternator

2.

Probable

shift

battel)l.

connections

battery

run

pressure

switch

not

ch'cult

breaker

solenoid

batlel)l

connections.

solenoid

to

solenoid

not

in

switch. solen'oid.

battel)l

connecllons.

fuel

solenoid.

fueling

system.

solenoid

power.

DC

allernator.

fuel

solenoid

switch.

Cause

tripped

resistance

battety

connectIons.

alternator charge

not

notop,retlngl.

circuit

IIrlve.

on.

tripped.

on

not

operating.

faulty.

neutrel.

to

fuel

faulty.

shut-off

will

not

leak

to

leak.

charging

faulty.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

solenoid.

cable.

de-en~rgize.

ground.

1.

2.

1. 1a.

1b.

2.

3. 3a.

1.

2.

3.

1.

2.

3.

4.

5.

1.

2.

Verilicallon/Remedy

Check

switch

andlor

Reset

breaker; n breaker

circuit

and

check

Check

the

preheat Check

engine Check Check

Gear

HURTH

Check Check Check Check Check

.

~ollage

solenoid.

(+)

connection

ground solenoid connection.

shift

must

HSW

switch

wilh

that

12 battel)l battel)l

connections.

Check

that

fuel

Check Check

Fuel fuel

Check

Swllch Replace

Remove Check

offlhe

Manually

Observe

Is

lines.

12

run

solenoid.

that

fuel

for

air

filters

clogged.

system.

solenoid.

to

combine

batteries.

Exc.

connection

lu.1

adjacent

Check after

Check Check

corrosion

Check

OC

Pertorrn

Check for

shut

to

the

if

gauges

not

running,

wirlng.lnsert.sensitiv,

(Do

not

short

is

all

wires

cable

connections,

ELECTRICAL

DC

7iJsting

the

drive

loose

connections.

volts

are

present

battel)l

connections.

Irlps

again,

shorts

to·

after

solenoid

battel)l

cable

for

voltage.

(see

NEUTRAL

at

the

althe

open.

Bleed filters

and

start

at

alternator:

lever.

down

on

lights

pressure

(0

-

Remove

rise

at

battery

belt

tens10n,

of

g.n.retor

Circuit

alternator

output

Exc.

terminal.

check

ground.

the

air

and

batteries.

Pul11ever

using

the

are

.25

for

circuit

for

both

al

and

to

starter

stUd.

Check

"s"

terminal

be

In

neulrel

TRANSMISSIONS).

ohmmeter.

volts

are

present

connections.

charge

state.

volts

are

present

valves

are

In

fuel

system. Replace

house

connection

at

shut-off

the

engine

throttle

lever

and

panel

Test

the

oil

start

engine.)

located.

for

temperature

connections

check

SYSTEM/ALTERNATOR.

voltag.

check

B,Uety

Charging

belt

tension;

Check

at

the

preheat

solenoid

breaker

on

Ihe

and

(-)

connection

connections.

SWITCH

solenoid

connection.

(+)

connection

from

fuel

system.

bleed

air

from

repair

alternator.

back

the

shut

engine.

aclivaled

switch:

connections

to

when

amp)

meter

locate

the

loose

connect10~S,

test

alternator.

charging

under

on

to

close

off

lever

In

battel)l

and

replace

fault.

circuit.

to

the

.nglne

See

.

should

turn

freely.

with

Voltmeter.

Check

Ensure

12

EI1g1nes

35

(continued)

& Generators

ENGINE

JROQBLESHOOTING

Engine

slows

Engine

overheats/shuts

Engine

alarm

Engine

alarm

Exhaust

smoke

Problem

and

stops.

sound

pulsates.

sounds

continuously.

problems

down.

1.

Fuel

lift

2.

Switches

or

disconnected,

3.

Fuel

4.

20

Amp

5.

Exhaust

6.

Water

7.

Air

Intake

Raw

1.

Coolant

2.

1.

Loss

Oil

pressure

2. Engine

1.

High

2. too

1.

Blue

Whita

2.

3.

Black

Probable

pump

failure.

and/or

starvation.

circuit

breaker

system

Is

In

fuel.

obstruction.

water

not

circulating.

not

circulating.

of

oil.

switch.

coolant.

temperature

Iowa

tamperatura.

smoke.

Cause

wiring

loose

tripping.

restricted.

switch

opens

at

VerilicationJRemedy

1.

Fuellift

pump

should

pump

with

spare.

2.

Inspect

wiring

Inspect

switches

3.

Check

fuel

supply,

4.

Check

for Ensure causa

5.

Check exhaust

6.

Pump bleed

7.

Check

1.

2.

2a.

Thermostat -remove

2b.

2c.

2d.

1.

2.

1.

.

2.

1.

la.

2. 2a.

3. 3a.

3b.

3c. 3d.

high

breaker

tripping.

for

blockage,

elbow.

water

fuel

system.

air

intake

Raw

water

pump

Obstruction

Replace

thermostat.

Loss

of

coolant -check

for

leaks.

Broken

or

ioose

Air

leak

in

bleed

Check

01\

Replace Check Check

check

Incorrect Crankcase

through Engine

system;

air.

Add

dipstick,

drain

hose

oil engine for

satisfactory

with

grade

the

Is

running

Faulty

injector Improper Fuel

grade

burn

incomplete

insufficient air

exhaust

system;

Improperly

Lack

of

air -check

Overload.

make a distinct

for

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

from

fuel

tank(s);

failure.

Check

at

raw

water

Intake

and

hoses,

belts -tighten/replace.

run

engine

coolant

as

needed.

look

for

oil

connection.

pressure

switch.

coolant

level.

of

angine

overfilled

axhaust).

cold.

or

Incorrect

offuel.

for

proper

check

injectors

air

oparation

replace

with

due

air

Intake.

ohmmeter,

is

timed

ticking

and

loose

operation.

fuel

lift

pump.

draw

during

sansitiva

to

heat

hose,

carbon

change

filters

Impeller -replace.

or

raw

water

test

in

hot

water.

hose

clamps,

and

open

the

leaks

at

oil

filter

with

switch

if

faulty.

oil.

engine

oil

(oil

injector

timing.

to

high

back'pressure

combustion

intake).

or

valves,

Check

(check

or

poor

for

sound.

Replace

connections.

operation.

which

would

buildup

at

and

filter.

drain

plug,

pressure

cap

and

at

bypassed,

is

blowing

out

in

exhaust

for

restrictions

compression.

proper

ventilation.

etc.

to

or

in

)

Engines & Generators

36

NOTE:

The

located

CONTROL

MANUAL

engine

on

the

STARTER

contro(system

engine

as

close

PANEL

TROUBLESHOOTING

DISCONNECT

is

as

possible

protected

to

by

the

a power

(TOGGLE

20

amp

manual

source.

SWITCHES)

reset

circuit

breaker

Problem

PREHEAT

fuel

depressed,

solenoid,

preheat

solenoid

START

SWITCH

engagement.

NO

IGNITION,

NOT

CHARGING

BATTERY

RUNS

no

electric

cranks,

panel

fuel

pump

not

energized.

DEPRESSED,

does

BATTERY

DOWN

Indications

and

no

starter

not

slart.

1.

Oil

Pressure

20

amp

2.

Connection

1.

2.

Faulty

3

..

Faulty

4.

Loose

Low

5

Faulty

·1.

2.

Check

3.

Faulty

1.

Faulty

Oil

1.

High

2.

3.

Low Faulty

4.

Probable

circuit

to

swilch. solenoid.

battery

battery.

fueling

for

air

fuel

lift

alternator

pressure

resistance

alternator.

Cause

switch.

breaker

tripped.

solenoid

faulty.

connections.

syslem.

In

Ihe

fuel

system.

pump.

drive.

switch.

leak

to

ground.

leak

to

ground.

Check

1.

Reset

2. circuit

1.

Check Check

2.

Check

3.

4.

Check

5.

Check

1.

Check

2.

Allow

3.

Replace

Check

1. lurns

output

regulator Observe

1.

engine

Check

2. lines after

Check

3.

After a good

4.

If

replace.

Verilication/Remedy

switches

andlor

breaker.

If

and

connection. switch

that

battery

for

system

freely.

(Do short

leakage

it

run

circuit

with

12

yolts conneotions.

battery

charge

fuel.

to

bleed.

fuel

Uft

pump.

Ihe

d~ve

belt

Check

with a voftmeter.

lerminal.

jf

the

gauges

is

not

running.

Ihe

wiring.

NOT

start

is

located.

all

wires

for

battery

slops.

battery

opens

again,

for

shorts

ohmmeter.

are

present

state.

and

Its

lension.

for

loose

Ensure

and

panel

Test

the

Insert

sensitive

engine).

Remove

temperature

charging,

Remove

alternator

connections.

check

preheat

to

ground.

at

the

solenoid

Be

12V

are

lights

are

pressure (0-.25

connections

rise

to

locate

and

sure

present

activated

amp)

alt.ernator

bsnch

connections.

oil

disconnect

solenoid

connection.

the

alternator

Check

Ihe at

switch.

meter

and

the

fault.

test.

Ihe

when

In

battery

replace

at

output.

Repair

the

or

TROUBLESHOOTING

If

the

gauge

reading is

by

the

gauge

when the instrument panel

step

is

to

check

and

the

Negative

•

Assuming

that tilere is

instmment panel energized and perfonn

1.

Discounect

gauge

the sender

reads

situation.

2.

Remove gauge scale,

the wire

and

connect

which is the nonn.l reading for

other

than.

for

12

volts

DC

between

(B-) tenninals of the

12

volts

as

wire

at the gauge

zero,

which

is

the

attached

it

to

ground.

to

the sender tenninal at

what is

gauge.

required, leave the

nOlmal

See

WATER

nOlmaJ.Jy

is

energized, the

the

ignition (B+)

the

following

and

see

reading

if

the

gauge

11ris

situation.

"tIY'

TEMPERATURE

indicated

steps:

if

the

for

tlris

tlle

reads

first

full

If

undoubtedly conductor

If

probably Assuming

sender Check that

Some

WESTERBEKE

Engines & Generators

'37

AND

both of

either of

defective

to

starters battery terminals), to

11le

is

block.

OIL

PRESSURE

the

above

gauge

OK

and the

from

the sender

the

above

and

the

gauge

tlle

sender tenninal

the

engine block

have isolated

cOimected

the

ground

tests

problem

to

gauge

should

is

QK, check

to

tlle

starter

side

will

GAUGES

are

positive,

lies

tl,e

gauge or

tests

are

negative,

be replaced. .

tlle

at

the

gauge for

is

connected

ground

!enninals

(both

not necessarily

the

eitller

with

conductor

continuity.

to

the

and

plus

aud

the

tlle

be

gauge

tlle

sender.

gauge

from

ground.

if

tlle

minus

connected

is

the

NOTE:

WESTERBEKE

engine

adjustments

mechanic.

ENGINE

ADJUSTMENTS

recommends

be

peiformed

The

information

below

that

the

by

a competent

is

provided

following

engine

to

assist

the

ENGINE

The boat

peller idle

The rpm

this stall produces.

ADJUSTING

1.

2.

3.

4.

IDLING

engine

is

operating

size,

speed.

normal at

normal

rpm

range

when

Loosen

fuel

injection

Adjust the

engine

Tighten

Race

the

remains

idling speed

shaft

idle speed

engine

the

the throttle

THE

the locknut on

the

bolt

at a quiet

the

locknut.

engine

as

set.

SPEED

is

in

the

water

length,

and

for

operating

engine

is

restarted

IDLE

pump.

so

that

idle.

several

pre-set

at

the

factory

other variables

the

transmission

these

engine

models

temperatures.

operates the

and

smoothest,

no

damper

SPEED

the

idle adjustment bolt on

the

throttle control lever will

(1000-12000

times to ensure

rpm)

the

but once the

such

as

pro-

can

affect

is

1000-1200

Where

does

chatler

.

idle

speed

the

ever

not

the

hold

is

in

STOP

CONTROL

ENGINE

POSITION

STOP

ENGINE

STOP

ADJUSTMENT

CABLE

CONTROL

WILL

DOWN.

SO

I

THAT

SHUT

THE

IOLE

THE

HIGH

ADJUSTMENT

SET.

'

4n.lIlOTM<I'T

SPEED

IS

FACTORY

BOLT

OPTIONAL

The fuetrun engine'S pump.

new

1.

Visual To

below

2.

Threed

amount

3. Thread the observe the solenoid plunger through

Allow

into

push

4.

Back position

5.

Properly

6.

FUEL

solenoid

block just

Proceed

fuel

obtain

LOCKNUT

solenoid.1\vo harness adjacent

Re-assemble

unit.

energized.

solenoid

run

access

the

of

the

injection

the

Make

as

solenoid.

to

this,

fuel

locknut

Teflon

solenoid

plunger

solenoid

with

TORIlUE

connect

and

the

inboard

the

certain

If

it

in

1/8 -1/4

RUN/SHUT-OFF

is

mounted

aft

of

and

below the engine's injection

follows

remove injection

the

when

the

fuel

injection

the

pump.

onto

the

sealant

to

into

to

contact pump. into

the

out 1/4 -

locknut

VALUE

the

three electrical

of

the

connections

third

grounds

threaded hole

shut-off

the

unit

does

not

and

tum

shut

solenoid

the

the hole on

Do

solenoid.

lever

stops

only

till

SOLENOID

in a threaded hole

installing a replacement

pump's

fuel

off

lever

and

then

threads

on

the

engine

the

fuel rack

not thread further

112

of a tum

28.9-36.2

to

with

when

goes

shut-off

and

Ff-LO

leads

plug

into the

the

engine block an

8mm

gasket

the

solenoid

to

idle.

is

obtained.

on

rack

is

gasket

just

apply a small

solenoid.

and

cover

opening.

and

move

so

secure

(4.0-5.0

from

the

engine

bolt.

and

test

Threed

the

or

needed.

fully

as

to

it

in

M-KG)

at

an

run

the

is

dethe

FUEL

RUN

SOLENOID

'"IIY'

WESTERBEKE

Engines & Generators

38

NOTE:

.

ments below

ENGINE

WESTERBEKE

be

peiformed

is

provided

to

ADJUSTMENTS

':;'commends

by

a

competent

assist

the

that

engine

mechanic.

the/allowing

mechanic.

engin~

adjust-

The

information

ENGINE

Check; openiting'houis

Remove

compression at

MEASURING

Check

remove

shut-off the tester motor this

matically of more

COMPRESSION

the engine's

each

glow

pressure.

280

rpm.

COMPRESSION:

LIe

compression

all

fuel

solenoid

injector

the

on

the

until

process

others.

than

hole

adapter

the

for

Cat

least

35.5

compression

or

whenever

plug

and

The engine's cranking

pressure.

injectors,

wire,

or

pressure

.each

Compression

psi

glow

and

cylinder.

20%)

C2.5

or

and

plug

cnmk

reaches

lower

kglcm')

pressure engine check

glow

install a compression

hole.

the

a maximum

Look

compression

pressure

at

perfonnance

each

cylinder's

To

do

this wann

plugs,

disconnect

Connect a

engine

with

for

cylinders

should

280rpm.

500

speed

compression

value.

than

not

and

is

reduced. is

the

adapter

the

starter

with

the

differ

1250

engine,

the

fuel

in

Repeat

dra-

average

by

DRIVE

Excessive and A slack belt slipping, resulting

The deflected inch (l2mro) midpoint beli.

Adjusting

1.

2. Loosen

3. With

4.

S.

BELT

ADJUSTMENT

drive

reduce

the

service

or

the

drive

belt

is

no

less

as

between

A spare bolh,r belts

A

WARNING:

drive

helt's

tension

Belt

Loosen

belt is Tighten

Check

.

operation.

the

alternator

the

alternator

the

alternator

tensioned

both

the

tension

belt

tension

life of

presence

in

high

properly

thim

3/8

the

belt is

the

tv(o

Never

while

Tension

loose,

correctly.

bolts.

again

can

cause

the

of

oil

operating

adjusted

inch

ClOmm)

depressed

pulleys

should

attempt

the

engine

pivot

bolt.

alljusting

swing

after

rapid wear of the belt

fresh

water pump's bearing.

on

the

belt can cause belt

temperamres.

if

tlie

belt can be

and

no

more

with

the

thumb

on

the

longest span

always

be carried

to

check

or

adjust

is

in

operation.

bolt.

it outward

the

engine

l1I1i:i!

has

on

been

than

at

of

board.

the

in

1/2

the

drive

If a weak

is

either for cyliilder

. cylinder

comes

Abnormally carbon accompanied

NOTE:

cause

TORS.

fuel

cylinder

valve

the

weak

is

still

to

seal

up

-the

accumulations, a condition

In

case

may

be

Poor

pressure

faults.

When

re-installing

COMPRESSION

STANOARD

MINIMUM

MAXIMUM

ACCEPTABLE

is

or

piston

cylinder,

low,

the

rings

high

readings

by

high

of

severe

fuel

injector

fuel

quality.

to

the

VALUES

(AT

280

(AT

280

flanked

apply a small

are

by

related.

adjust

as

and

repeat

faulty.

on

pressures

all

vibrations

problems,

contaminates

injection

RPM)

DIFFERENCE

glow

pump

plugs

398.16

355.5

healthy Check

the

needed

amount of

the

.

cylillders

that might

and

noise.

and

detonation

and

test.

see

and

will

result

.

use

anti-seize

PSI

(25Kg/cm"

BETWEEN

cylinder,

valve

test

again.

oil

If

compression

indicates

be

FUEL

loss

in

(28Kg/cm')

35.5

PSI

the

problem

clearances.

If

the

into

the

heavy

noise,

the

INJEC~

of

positive

injector

compound.

(2.5

Kg/em"

Engines & Generators

39

NOTE:

WESTERBEKE

ments

be

below

is

ENGINE

peTjonned

provided

by a competent

to

assist

ADJUSTMENTS

recommends

the

that

engine

mechanic.

the

following

T(lechanic.

engine

The

infonnation

adjust-

TESTING

To

test gallery place. gauge.

OIL

PRESSURE

NOTE: A newly

reading

pressure

del,eruljng

OIL

PRESSURE

WITH

ADAPTER

THIS

MECHANICAL INSTALLED THE

OIL

WHERE

ENGINE

PRESSURE

OIL

PRESSURE

oil

pressure,

and

install a mechanical

After

warming

BETWEEN

started,

up

to

70

or

reading

GAUGE

BLOCK

as

upon

the

TEST'

GA1JGECA~

THE

OIL

OR.

IN

SENDER.

PLACE

remove

80

low

the

up

the

engine,

35

AND

cold

engine

psi. A wanned

as

30

load

placed

TESTING

HU~H~'

I

cH;

OF

THE

hex

head

plug

oil

pressure

read the oil pressure

55

PSI

may

have

engine

psi.

Oil

pressure

on

the

engine.

DlL

PRESSURE

from

gauge

an can

will

the oil

in its

oil

pressure

have

vary

an

oil

OIL

PRESSURE

The

all

pressuterelief valve cover just in place pressure pressure

OIL

There

oil gallery the panel (5-10 continuously.

NOTE:

will

below

by

is

approximately

in

PRESSURE

is

an

to

alarm

psi).

The engine alarm

This

shut

off

a

22mm

the

engine's

oil

pressure

monitor

alann

once

RELIEF

the oil

pressure

hexhead

lubricating

SWITCH

switch

the

buzzer.

should a low

will

sound

il-ie

oil

pressure

VALVE

is

located.

senders

plug.

45

psi

and

connected

engine

oil

buzzer

when

in

the

location.

This

valve's cracking

operates

system.

into

pressure

oil

pressure

in

such

starting

exceeds

5-10

front

to

maintain the

the

and

to

issue occur

cases

the

engine

psi.

gear case

It

is

held

engine's

sonnd

will sound

and

A

CAUTION:

checking

rotating

and and

LOW

A ings. A rapid

failure.

ings,

flywheel. do

OIL

gradual

For

see

parts

not

loss

the

Be

sure

to

the

engine.

wear

such Keep

music

Keep

as

the

long

hair

earphones.

PRESSURE

of

oil

pressure

loss

of

oil

pressure

additional

ENGINE

information

TROUBLESHOOTING

stop

the

your

hands

cooling

away

usually

indicates a

on

engine

bef~re

away

from

fan,

v·belt,

pulleys,

from

rotating

indicates a worn

specific

low

oil

pressure

chart.

parts

bear-

bearing

,ead-

Engines & Generators

40

ENGINE

NOTE:

WEST.ERBEKE adjustments TIW

information

be

performed

below

ADJUSTMENTS

recommends

by a competimt

is

provided

that

to

the

assist

fallowing

engine

the

mechanic.

engine

mechanic.

CYLINDER TIGHTENING

SUB

Cylinder head adjustment.

TORQUING

After

the

cylinder head Loosen the cylinder head

shown. the

sequence

rocker cover stud securely. .

HEAD

BD,LT

SEQUENCE

BOLTS

bolts

must

be

tightened

THE

CYLINDER

initial break-in period (approximately

bolts

should

(The

engine::

should

shown

below.

HEAD

be

re-torques.

bolts

be

cold).

One

one

bolt

half

Then

at

before

valve

BOLTS

turn

in

tighten

a.

time.

50

hours),

the

order

the

Tighten

bolts

the

in

W\LVE

The hours

Valve cold.

CLEARANCE

valve

or

adjustment

Cold

clearance

whenever

engine

ADJUSTMENT

must be

the valve

should

valve

adjusted rocker

only

be

clearance is

'INSPECTION

every 500 operating

is

abnormally

done

O.OIOin

when the

noisy.

engfue

(O.25mriJ.).

is

~~~=O.lnOiin(0.25mm)

VALVE

CLEARANCE

TIMING

MARKS

NOTE:

The

rocker

shaft

,

access

to

the

cylinder

TORQUE

Bolts

ROCKER

All All Rocker shaft hold-down

head

Rocker Cover Hold Down

SPECIFICATIONS:

#1,

#2

'14.4 -

#3,

#4, #5,

#6,

SHAFT

main

bolts

sub

bolts

are

fiats.

head

21.7Ib-H #7, #8, -54.2 -51.4Ib-1t

HOLD-DOWN

are

14mm

12mm

assembly

bolts.

(2.0 -3.0

BOLTS:

across

the

bolts

are

Cap

should

Kg-m)

(7.5 -B.5

the

bolt head

l2mm

Nuts -

be

removed

fiats.

across

(IOmm

for '

'

Kg-m)

,

the

bolt

socket) (snug)

IT.

MARK

ON

PULLEY

.

1.

Pull off the

and clearances when

2.

Adjust

(TOC) of

_care

pnlley as

shown

not exactly

piston,

3.

Confirm

the crankshaft i,turned the

4.

Align

,cylinder

o clearances

No.1

aIr

take

off therecker

at

IDC

they

are

all

valve

the

compression

to

align

the

exactly

on

the illustration

aligned,

depending

that

TOC

mark.

the

mark

on

its

for

cylinder with the engine

breather pipe

(Top

on

their compression

clearances

TOC

with the'indicator mark

the

on the position of the

the

valves

(as

shown) for

compression stroke and

both intake,andexhaust

cover

Dead

stroke

timing

valves

do slightly

from

bolts.

Ceriter)

at

the

mark

below.

may

not

move

IDC

cold.

the'TOcker

Adjust the

Top

fore.l"'h

in either

for

stroke.

Dead

on'the

em

If these

be

pushed

carn

up or

for

the

adjust

valves

cover

valve

each

cylinder

Center

cylinder.

crankshaft

the

gear

marks

up

lobe.

down

direction

No

.. the for

Take

case,

are

by

the

when

from

1

valve the

41

NOTE:

WESTERBEKE adjustments information

VALVE

5.

Injection

The shut·off lever (throttle)

the throttle fully open

fuel will Remove

crankshaft

1. Remove the high pressure

2. Remove the

3. Reinstall only the delivery valve holder

CLEARANCE

When setting follows:

a. For the two engine

the

No.1

cylinder, rotate

(as

viewed from

valve clearances

the

No.2

for

Rotate the crankshaft another 240 clockwise position theNo,2 cylinder at clearances for the No.2 cylinder.

Pump

flow

to the injection

the

cylinder glow

to

be easily rotated.

No.1

injector and

"0"

ring

and remove

the

holder.

high pressure that

the

end that pointing away line during the timing

ADJUSTMENT

IDe

for

the

No.2 cylinder proceed

(2

cylinder) from

the

front

for

both

cylinder.

both

the

intake and exhaust valves for

Timing

No.1

fuel

would

from

Adjustment

must

while

making

pump.

plugs

fuel

the

No.1

fuel

delivery valve holder over the

the

delivery valve spring beneath

line to

the

connect to the fuel injector is .

the

engine.

check.

(CDNT.)

the

crankshaft

of the engine)

the

intake

IDC.

Adjust

be in the

these adjustments or

to

allow the engines

line from between the

delivery valve

delivery

holder.

Fuel will

ENGINE

recommends

.be

petformed

below

is

provided

as

IDC

for

1800 clockwise

and

adjust

and

exhaust valves

to,

the

valve

(Spill

Timing)

run

position

.

and

flow

holder.

re·attach

Attach it

from

and

this

ADJUSTMENTS

that

the

by

the

no

the

so

following

a

competent

to

assist

engine

the

mechanic.

Rotate

the

rotation

compression stroke. Move

the (as fuel

(no crankshaft pulley should be directly aligned with the timing indicator

If

attained,

thickness

to

the electric lift viewed

line, until the instant

drips).

on

the

specified

adjust

mounting Changing the shim thickness by the

injection timing by approxilllately one degree. advance the timing, decrease To

retard

engine

mechanic.

engine's crankshaft position piston

, .

throttle lever to

pump.

from

the

front), catching

At this instant, the

the

front of the gear case ±

injection timing

the timing by increasing or decreasing

of shim material under

flange

to change the injection timing point.

the

timing,

HIGH

PRESSURE

FUEL

LINE

The

in

No.1

at

its

full

Slowly rotate

the

fuel

190 BIDCtiming mark

(190 BIDC) can not be

0;004in

tile

increase

the

its

normal

direction of

the

beginning

open position and operate

the

crankshaft clockwise

the

friel

completely stops

the

injection pump's

shitt! thickness,

shim thickness,

of

from

.5

degrees.

(O.01mm)

its

the

No.1

flowing

on

changes

To

as

required.

as

required.

the

,

IT

MARK

ON

PULLEY

"'iIV'

WESTERBEKE

Engines

42

1I<:4eneratprs

FUEL

INJECTION

'!\,-+---t'"'"'

...

PUMP

FUEL

CONTROL

RACK

FUEL

INJECTORS

NOTE:

WESTERBEKE

adjustments be peifonned

information below

REMOVING

NOTE:

1.

Disconnect

and and bending

2.

Using a 17mm entirety the

return

NOTE:

prior

any hole.

by carbon build-up or side lift

3.

The injector washer.

and

reinstalled.

FUEL

Injector must

loosen

move

them

the

from

two

sealing

l.ine

,to

Clean

to

lifting

rust

or debris

If

the

with

the

it

out

..

This

replaced

recommends

is

provided

INJECTORS

be

serviced

the

high

the

lines

out

of

lines.

long

the

top

washers

each

injector.

the

area

it

out

from

injector

aid

of

seats

in washer with a new

NOTE:

adjustments infonnatlon

by

a competent

to

assist

in

pressure at

socket,

of

of will the

the

should

fuel

their

attachment

the

way

remove

the

injectors.

and

banjo

around

the

cylinder head

falling

not

lift out easily and

the

like,

socket wrench

cylinder head

be

washer

ENGINE

WESTERBEKE

be

peifonned

below

that

the following

engine

the

mechanic.

a "clean room"

lines

from

to

the

of

the

injectors.

the fuel return

Take

care

bolt that attaches

the

base

of

the

to

down

into

the

work

the

injector

to

free

on a copper

removed

when

with

the

injector

ADJUSTMENTS

recommends

by

is

provided

engine

mechanic.

environment.

the

injectors

injection

injector

help prevent

injector

is

it,

the

Avoid

line

not

to

held

side-to-

and

sealing

injector

is

pump

loose

the

in

then

that

a competent

to

assist

The

in

its

fuel

the

following engine

engine

mechanic.

the

mechanic.

INSPECTING

1.

Operate one correctly injects strips.

defect. clogging carefully

DRIP

2.

Apply by

nozzle on replaced. A very remain indicate a defect.

A

nozzle

deeply

THE

the

hand lever

stroke

per

in

its

fuel

in

Also, a spray

These

with

cleaned before

TEST

the

pressure of

operating the

the

tip.

If

bottom, it

on

the

WARNING:

is

of

Into

destroying

The

SPRAY

second axial

an

oblique

defects

dust

hand

it

drips

small

tip

such

the

tissue.

PATTERN

of

the

nozzle

tester

at

intervals of

to

check

if

the

fuel

is

injected

direction. A nozzle

direction

in

the

form

may

sometimes

and,

therefore,

reassembly.

"~.~

1635

kg/cm'

lever,

and

or

has a large

is

considered

amount

of the

The

velocity

skin

If

nozzle;

spray

of

fingers

it

enters

defective

that

is

defective if

or

in

several separate

of

particles

be

caused by

all

parts should be

00'"

(115

1b/in')

check

the drips from

accumulation of

and should

of

fuel

may

however,

injected

it

and

the

this

from

may

penetrate

hands,

bloodstream,

it

indicates a

~

sometimes

~m

({.

:i!

to

nozzle

the

fuel

be

does

not

the

FUEL

INJECTION

(140

TO

150

kgl/cm')

INJECTION

PRESSURE

INJECTION

1.

Using injection limit, adjust testee,

CHATTERING

TEST

TESTING

the

nozzle

starting

take

PRESSURE

13.7310

TEST

tester, pressure

or

replace

the

following

NORMAL

~~\\'

'I'"

•

,!

I I \

1991

TO

2134

14.71

check

of the

the

precautions:

'&;],

psi,

MPa

the

spray pattern

nozzle.

When

lEf1J

, I

~!

FAULTY

I:~'

,\

~

,

",.N:OllILEINJECTION

INSTALLING

Install

the

order

of

removal.

holder

assembly,

and

If it

exceeds

using a

the

nozzle

',I@

I.

-',

FAULTY

,:i

1",',

\',".

"W'WESTERBEKE

Enginell&cGenerators '

! -

-~--.--.

--,'

'.

-

43

nozzle

and

nozzle

When

installing

use a new

holder

copper

assembly

the

nozzle

washer_

in

and

the

roverse

nozzle

JS

AND

BW

TRANSMISSION

DESCRIPTION

The

transmission's gear ratio mission The

and,

cllITied the Before tested things, oil

agains~

properly The

transmission up

on

'oil

transmission.

may

rotates opposite

JS

transmits

in

reverse,

out

transmission

leaving

with

provides

acts

as

corrosion

stored.

JStransmission

the

dipstick with

exclusively.

have

its

an

by a servo

is

the

oil

in

the

all

a preservative, providing reliable protection

to

Multigrade oils

DO

an

API

power

intennediate

NOT

factory,

transmission.

internal

for

at

is

or

SAE

NOT

specification of CF

is

2.47

to

I.

This manual trans-

to

the

engine

when

in

with

case-hardenedheli,al

gear.

The

revei.'~i.ng·piocess

double

disc

system. For safety

filled

with

lubricating

each

transmission

This

testing, arnol)go)her

parts

with a coating of

h~ast

one

year

if

the

transmission

an

immersion-lubricated

near

the

top

of

the

machined notch cut

.20

W/20 or SAE30 weight engine

are

not

tobeused

mix

grades

of

oil!

Lubricating

or

CG-4.· .

forward

for

shipment.

is

th9roughiy

oil.

type.

iIi

gear.

gears

reasons,

This

is

Fiil

the

this

oils

IS

LUBRICATION

The

oil

capacity

quart

(1.0

been

warmed

tained

at

the

dipstick

ing.

Make sure that

are

in

good shape.

place.

Change operation

minimum). for from

approximately also be removed by insertirig a pumps tube into the opening

for·the dipstick and extend it to the bottom

then pump out the oil.

the

draining

the

for

the

JS

transmission is approximately

liter).

Check

the

oil

level

and stopped.

the

top of

is

completely

These

transmission oil after the fhst

and

thereafter every

The

JS

the

oil.

transmission,

10

to

The

the

machined /lat

inserted

the

two

a-ring gaskets

a-rings will keep

has

a 6

mm

To

make sure most

run

the

15

minutes

oil

250

Allen Hex

engine

to

daily after

level should

on

the dipstick

into

thetransmissibil.

on

the:dip~tic"ic

25

hours

hours lor

warm

once

wnmch

of

the

in

NEUTRAL

9i!..ThlS

of

the

engihehas

be

roBin-

when

the

dipstick

in

. .

of engine

per

year,

drain plug

oil

will

drain

for

ollmay

the case and

1.0

hous-

CONTROtS

The

only

controls required

single

level

remote controled cable. The cable should

attached plied with the unit Both control lever mllst

cable-

cable

FORWARD

tion

inches

transmission's

positions.

to

the

gear

is

attached

an

equal

without running

of cable

to

throwdistanc.e to shift the gellfbox

or

into

throw

gear

be

to

operate

box

lever using

the

gear

in

the NEUTRAL position

the

gear box lever. This allows

REVERSE from the

out

of cable. Allow approximately I

from

the

box

lever

to

the

transmission

the

cabi" bracket

b~x

lever

aDd

NEUTRAL

NEUTRAL position on

each

o(the

hvo

..

the remote

when

the into

drive

. .

is

a be sup-

the

remot,

posi-

tp.e

112

If

the

throw distance

short,

.the

gear

into

.FORWARD

mission's internal clutches will wear prematurely transntission

:::,-

::::I··

.f,

Excessive

detrhnental remote

ing.on

NEUTRAL.

..

!l'l-

O====¥.t=-;:::=~

throw

to

control lever should align with

its

bracket

..

".

-'

~EVER;E

(or

travel) of

box

lever cannot

or

REVERSE.

may

over

heat and eventually fail.

distance

the transmission. Note that

~

wheil

GEAR

1112"

in

the

.

BOX

. .

the

fully

In

the

remote

transmission

SHIFT

I

~ • -~

.1

NEUTRAL

SHiftiNG·

Toshiftthe-transmissiOllfron NE(jTRAL

exert'a heavy push may

nbt

carry sion's internal mission rembte·control.Jeveris season

l200tpm or below.

not

•.

Shift the transmission while the engine is running at

A

CAUTION:

gearbox/ever

this

plate:andtheactuating

transmission ensure

equal

Loosenliig.ofthls

transmission

to.

the

enough

gears; A gentle

engaging

force

.into

NEVER

cover

has

been

throw

cover's

warranty.

remote control

to actually

throw

thi

desired

lubri.cated

remove

from

transmission.

level

finely

adjustedatthe

distance

of-internal

capscrews

is

drive.

at.\east

Dr

loosen

Inside

remote

cable

is

too

engage

the transmission

this'

situation, the trans-

and

the

control level

the

NEUTRAL

is

really

is

position of

in

not

the

mark-

LEVER

\

.

\I'z:'~.-~\

'FORWARD

into

FORWARD,

lever.

A.gentle throw

shift·

the

transmis-

signalled by the trans-

Make sure

once

each operating

the

two-bolt

The

position

of

the

factory.to

mellhanisms.

voids

the

.

the

of

Engines & Generators

44

JS

AND

BW

TRANSMISSION

BELL

HOU:SING,

SAILING

The while sailing propeller transmission transmission will not in

OPERATION

JS

transmission'should

sailing,

Leaving

alleviates

is

able

is

left in

NEUTRAL

is

the

unnecessary

to

freewheel

its

be

just

good

COOLING

The

JS

transmission the transmission the

base

of

the

transmission's lubricating

through

bell

housing.

WATER

is

raw

be

left

in

transmission

drag

on

(spin).

FORWARD

daruaged.

a stainless

oiL

(Leaving

sailing practice).

water-cooled.

This

water

i~,

NEUTRAL position

in

NEUTRAL

the

vessel because

However,

gear

steel

helps

if

the

while sailing,

the

transmission

Raw

water

inlet pipelpcated

to

ccalthe

ALLEN

DRAIN

PLUG

while

the

enters

the

at

SERVICE

If

any

seal

on

the

transmission

the

transmission

dealer,

llis

often

con1nbuted

transmission's coupling Disassembly

mended, be

done

by

looked

problem,

of the transmission

If

an overhaul

an

especially

to

an

authorized

improper alignment of the

MAINTENANCE

Transmission housing routine,

Periodically and

corrosion,

checking

'(fluid

maintenance

clean,

check

the

and

change the

inspect the transmission

Make

certain the

the

fluid

level

will

appear

as

strawberry

Lay-up/Winterize

Storage

waterwater

D

D Fill

D

requires special

NOTE:>This

D Inspect

operation will

cooling

Clean

up

areas

(use heat resistant paint).

the

transmission internal corrosion. (Extended or

more).

Loosen flange removing the boat

and

Look

the all

attaching

and

spray

the

for cmrosion of

conduit,

moving

system

the

transmission

hardware

propeller shaft coupling

from

with lubricant.

gear

shift

and

bending

parts.

shows

signs

of

leaking,

at

by

a qualified WES'IERBEKE

concerning

and

the

propeller shaft's coupling.

in

the

or

repair

is

needed,

WESTERBEKE service

is

minimal,

fluid

level

fluid

every

300

air

vent

look

for

signs

cream).

care.

Follow

usually

occur

is

properly

and

touch-up

with

SAE 30 engine

storage

from

the

water.

cable,

linkage,

the

end

flttings,

of the actuator rods. Lubricate

the

field

is

not recom-

the

Keep

the

as

part of your regular

operating

and

the

cooler

is

clear

of

water

these

procedures:

when

winterized.

any

oil

only,

the

transmission output

flange

before

Seperate the

and

attachments.

cracks

have

rear seal,

work should

exterior

and

contamination

the

unpainted

to prevent

12 months

centel.

hours,

for

when

engine

flanges

or

cuts

is

leaks

raw

in

JS

TRANSMISSIONS

General

Gear

Ratio

(Standard)

Propeller

(Direction

Propeller

Lubricating

Transmission

Capacity

OIL

ShaH

of

Rotation)

011

Sump

TEMPERATURE

Case-hardened

intermediate by

2,47: Right

See

SAE not grades).

1

SPECIFICATIONS

helical

reverse

servo

double

disc

1

handed -standard

propeller

20WI20

mix

qts

recommendation

or

SAE

grades

of

CF,

oil

CG-4,

API,

(1

liters)

250 F (120 C) Maximum

gears

with

gear.

Reversing

system

transmission,

30

exclusively

or

use

multi

or

SJ,

"MI'"

NOTE:

(twelve prevent

the

engine

an

out

chart

(Do

WESTERBEKE,

Engines & Generators

45

If

the

months

internal

back

transmission

or

more),

corrosion.

into

se11'ice.

is

to

it

should

Reduce

be

stored

be

topped

the

for a

oil

offwith

level

long

before

time

oil

to

putting

DESCRIPTION

The

infonnation below

Transmissions,

SECTION

A

the

shift

this transmisSion

the

TRANSMISSION

applies

to

CAUTION:

actuating

lever

mechanism

lever

travel

warranty

is

specific

all

models.

INCLINATION

The

position

Is

factory-adjust(ld

from

neutral

Is

in

any

way

wili

be

HURTH

to

the

Haw

ifBWJZF

TROUBLESHOOTING

of

the

mechanism

to positio'; A and·B. tampered

with,

behind

ensure

If

the

void.

equal

TRANSMISSIONS

NOTE:

When

installing shifting or

rod

is

not

linkage,

impeded

small a bending mount a

two on

SHIFT

The transmission Upon loosening the retaining

be moved (cable or not contact

distimce The control

the neutral

·should coincide with The shifting travel,

ating and B should be at least

the inner pivot point. . A greater amount

support

threaded

the

gear

LEVER

to

rod

between

actuating.

position

lever,

detrimental

is

slow

shorter,

in

clutch

Check

travel

which, generation by

NOTE

holes

housing.

any

linkage).

the

cable

shift lever

between

and

turn,

arid

for proper

the

transmission,

by

restricted

by

unsuitably

radius

for

shift

located

Refer

is

suitable

position required

actuating lever cover

lever and cover

or rod should be

of

the

as

of

is recommended.

proper clutch engagement might be impeded would mean premature clutch plate engagement

FORWARD

positioned

or

other

restrictions.

control

cable

above

to

the

for

single lever remote control.

screw,

Milke

certain

when

in

operating lever

the neutral position of

measured

the

neutral

position

35mm

for the

shift lever trayel

failure.

or

no

lever

travel

A

make

certain that

movability

guide

of

sheaves,

In

order

connections,

the

cable

bracket

WESTERBEKE

the

actuating lever can

for

the

control elemelllS

that

the shift lever

plate:

the

minimum

should

be

O.5mm.

arranged

the

neutral

at

the

However,

engagement

at

position. The

on

the

control console

this

pivot point

and

eM

outer

and

is

in

no

way

if

wear,

ex.cessive

This would

at

least

each

right angle

the lever

at

NEUTRAL

the·

cable

too

to

use

the

mounted

parts

list.

does

lever.

o.f

the

actu-

positions A

30mm

for

heat

be

indicated

all.

season.

.

REVERSE·

B

to

SHAFT

WESTERBEKE the bly The

required,

transmission bearing, provided the value specified under .

SPECIFICATIONS

shaft should

should be taken to prevent torsionpi vibratipn. When using a

universal joint shaft, manufacturers

Even

"Drivesaver" is a product

Rockland,

COUPLINGS

transmission and

mounted,

installation of a

since the propeller thrust will

be

with

the

coupling or

box boats flange

uDRlVESAVER"

bearings

or

where

and

stem gland

MA.

recommends a flexible connection

the

propeller shaft if the engine

in

order

to

compensate for angular

special

propeller thrust bearing

be

is

not

exceeded.

protected from additional loads.

make

certain' to observe the

instructions-. engine

solidly

caused

by

hull distortions, esp,cially

the

distance

between transmission output

is

less

of

Globe Marine

However,

mounted,

will

than about 800mm.

the

reduce stress in the

deflections.

absorbed

the

S,pecial

use

of

~

between

is

flexi-

is

not

by

the

output

care

flexible

gear:.

in

wooden

WESTERBEKE

'Englnes&.Gellerators

46

CONTROL CABLE

SHIFT

LEVER

O.5mm

MINIMUM

COVER

F

DISTANCE

HURTH

HBWJZF

TRANSMISSIONS

INITIAL

All stand safety

Fill

(DEXRON up

just insert the dipstick,

into

not Check also hoses,

OPERATION

HBWIZF

with

the

to

the

forget

make a Visual

marine

the

reasons

gearbox

II or DEXTRON ill). The

index

case

after

the

sealing ring

for

leaks

and

shift cables.

engine the

fluid

with

mark

the

and

change

inspection of

DIPSTICK

transmissions

at

the

factory

is

drained before

Automatic

on

do

fluid

Transmission Fluid

the

dipstick.

not

screw

level

is

um!er

the hexhead of

the

fluid

the

are

test-run

prior

fluid

To

it

in.

checked

after

coupling,

VENT

FLUID

LEVEL

on

to

delivery.

shipment.

level should

check

the

Screw

and

the

first oil

a test

For

fluid

the

dipstick tighten. the

dipstick.

25

hours,

cooler

be

level,

Do

and

LOCKING

Locking of required:

direction of the

WHEN

Rotation of

when river, stopped (for charging the battery), detrimental effects

DAILY

D.

o

[j

o Shift into

NOTE:

from

the

For additional information refer Transmission Section: SHAFf

AND

THE

PROPELLER

the

propeller shaft

use

the

gear shift lever

travel

for this purpose.

position corresponding

UNDER

the

as

well

SAIL

OR

the

propeller without

boat is being sailed,

as

operation of the

on

the

OPERATION

Check

the

transmission Visually Start

idle

the

idle

check

the

gear shift linkage

the

engine in

to

warm

gear.

Too

Iowan

transmission gear and

speed should

TRANSMISSION

neutral,

the

fluid.

idle

be

TROUBLESHOOTING.

speed

by

to

the

BEING

being

transmissioa

fluid.

will

increased

an

additional

position

Never

direction

brake

opposite ·your

put

the gear shift

of travel of

TOWED

load

(in

neutral),

towed,

or

anchored

engine

with

the

will

have

no

and

transmission.

allowing a few

produce a chattering

damper

to

the

following

COUPLINGS,

minutes

plate.

In

MAINTENANCE

is

not

in

the

boat.

such

as

in

a

prop~lIer

at

noise

such

cases

text

in

this

NOTE:

FLUID

Change operation, year orwhen you change engine oil.

CHANGE

the

fluid

for the

then

every

Re~oving

Push a the

bottom allows, from drain washer.

the

used

recheck

Drain

NOTE:

drain

this

A

engine dipstick

the

fluid

suction

pump hose down through

of

the

housing and suck out the

use

the transmission drain). Remove

the

bottom of

into

a container,

Wipe

down

fluid.

After running

the

fluid

level.

plug

lorque

When

plug

sealing

changing

sealing

washer.

·20·25

washer.

WARNING:

is

running.

hole.

This

.first

time after about

250

operating hours

the

transmission and

then

reinstall the plug

the

transmission and·properly dispose of

the

engine,

HJIbs

the

fluid,

take

The

drain plug will leak

Never

pull out

Hot

fluid will

could

cause

Keep

allow

shut

care

the

dipstick splash severe

vent

25

hours of

or

at

least once a

the

dipstick hole

fluid.

(If

the

drain

the

with

down

not

to

while

from

the

burns.

holes

clear.

space

plug

fluid

to

its sealing

and

lose

the

without

the

to

.

HBWJZF

General·

Gear

ratio

(optional)

Lubricating Transmission

Capacity

Propeller

Fluid

Rotation

TRANSMISSIONS

(Hurthl

hardened operated

HBW HBW100lZF10M HBW HBW

ATF -or

Sump

HBW HBW

Transmissions

SPECIFICATIONS

ZF

Standard

helical

multiple

50lZF

5M

150VIZF

15MIV

150NZF

15MA

Dextran·

50lZF

5M

100lZF

10M 150VIZF 150NZF

Transmission)

gears,

with a servo·

disc

clutch,

(2.05 : 1)

(1.79:1).

(2.13:

(1.88:

/I

or

11/

..

O.63pts

0.74pts 15MIV 15MA

turn

2.1pts

1.0pts

Right

1)

Hand

Case'

(0.3l)

(0.35l) (1.0L) (0.47l)

propellers·

Engines

47

& Generators

HURTH

HBWJZF

TRANSMISSIONS

OPERATING

A

is·

too

transmission

Normal should maximum

·reached Make

to

provide

TEMPERATURE.

WARNING:

high,

openiting

be

in

temperature

for

certain

good

stop

fluid.

the

range of

a short

there

ventilation

If

the

engine

temperature

of

time. is

enough

transmiSsion

fluid

immediately

of

the

transinission

122"F

(50'C)

to

266"F

space

and

(130'C)

cooling.

may

around

TRANSMISSION_COOLER

Some

WESTERBEKE

with

an

extemaIly

cooler. The

cooler

is

a separate

prevents

fluid. will, leaks.

A some

waters, WESTERBEKE

any

possibilities of

However,

in

time,

erode

transinission

circumst~ces,

maintenance,

model's

attached

patt

the

continued the

inside

cooler

may

depending

etc.

recommends

transinissions

convection

of

the

coolant

flow

of

the

last

ten

on

it inight

having a spare

type

transinission

diluting

of

coolant

cooler

yemor

operating

only

last half that

temperature

and

r:hlir:kthe

fluid

212"F

(IOO'C).

be

only

the

transinission

are

equipped

transmission

wltich

the

transinission

thrn

the

causing

more

hours,

cooler

external

but,

tropical

time.

aboard.

A

cooler

in

MAINTENANCE

1bmsinission

housing routine,

Periodicruly

and

corrosion.

Lay-up/Winterize

Storage

D

Drain with a proper

NOTE:

engine

D

Clean

(use

D Fill

vent"intemal

months

D

Loosen flange ing spray

D

Inspect Look the

all

maintenance

clean,

check

and

change inspect

Lubricate

requires

water

This

raw

up

the

heat

resistant

the

transmission

or attaclting

and

the

boat

with

the

for

corrosion

conduit,

moving

the

fluid

the

transinission

special

care.

from

the

mixture of

operation

water

cooling

transmission

paint).

corrosion

more).

hardware

propeller shaft

from

the

lubricant.

gear shift

of

and

bendiug

parts.

is

ininimal.

fluid

level

every

300

the

cable

connections.

Follow

transinission

antifreeze

will

normally system

and

touch

with

Dextran

(extended

fiom

coupling

water.

Separate

cable,

linkage,

the

end

fittings,

of

the

Keep

the exterior

as

patt of your regular

operating

and

the

these

oil

coolant.

occur

is

properly

up

III

storage

the

transmission

flange

and

actuator

hours.

cooler

.

procedures:

cooler

and

when

winterized.

unpainted

ATF

fluid

only,

before

the

flanges

attachments.

cracks

or

rods.

twelve

Lubricate

for

leaks

replace

the

areas

to

pre-

output removand

cuts

.

in

INSPECT

lEAKAGE

FOR

NOTE:

If

the

ltwelve

. fluid

before

For

months

to

prevent

putting

additional

HURTH

ZF

Industries

Marine

3131

SW

Lauderdale,

Fort Tel.:

(954)

Fax:

(954)

www.zF-Marine.com

transmission

or

more),

internal

the

engine

information

MARINE

US

Headquarters

42nd Street

FL

581-4040

581-4077

is

to

it

should

corrosion.

back

contact:

GEAR

33312

be

into

stored

be

topped

Reduce

service.

for a

the

long

time

offwith·

fluid

level

(

,/

En,glnes & Generators

48

HURTH

HBW/ZF

TRANSMISSION

TROUBLESHOOTING

CONTROL

The improper

'problems

rather

majority

clutch with

than

from

CABLES

of

transmission

adjustments

control cables

problems

HURTHIZF clutches, in

improper If you

shut the level, the full neutral,

observe

is stiff

and try excessively

cable

experience

engine

then

have

range

- from

into

full

the

actuating lever

to

operate,

again.

If

tight

adjustments.

operating

down. First

a helper

reverse,

break

it

is still

bends,

Problem

Transmission

Fails

Transmission

but

Delay

only

Transmission

Ch-attering

mainly

Boat

Oil

to

move

fails

to

of

gear

after

an'

at

fails

leakage.

gears

c~nnot

into

gear.

shifts

into

propel

the

boat.

engagement

increase

in

noise

becomes

transmission

low

engine

speed.

to

attain

specified

with

particular,

move

neutral

and

the

stiff,

and

be

shifted.

gear,

or

engages

speed.

louder.

noise,

max,

difficulties

(manual

(hydraulic

the

problems

check

the

to

back

on

the

cable

check

speed.

arise

transmissions)

·transmission are

very

sensitive

with

the

transmission.fluid

cockpit shift lever througb

full

forward,

to

neutral-

transmission.

loose

at

the transmission

the

cable

any

linkage

Actuating

1. Shifting

2. unattached.

Shift

3.

Output

1.

Propeller

2. Output

3.

Output propeller

1.

Lever

Refer Shift

2. Shift

3.

Damage

1. to

wear misalignment drlveshaft.

Beginning

2.

transmission

running

.

alignment

engine

1.

The

vibratIons

a

"chattering"

1.

Operating Operating

2. Corrosion

1.

Damag~d

2.

MisaQgnment

as

a result of

or

itself.

to

transmission,

back

to

while

you

If

the

remote

for

kinks

or

for

binding.

Probable

lever

level lever

engine

Cause

lever

is

loose.

cable

Is

broken,

Cable

radius

Is

binding

.

coupling

Is

shaft

is

coupling

travel N to B not

to

not

is

coupling

and

shaft

are

diagram.

travel

in

Is

binding

starting

or

fatigue,

between

damage

due

without

fluid,

of

transmiSSion,

output

or

propeller

in

the

noise

temperature without

at

radial

sealing

of

on

drive

output

bent

or

is

too

against

cover

not

turning.

equal

to N to

insufficient.

against

cover

flexible

coupling

possibly

due

engine

of

bearings

to

torsional

overload,

or

generates

unit

which

in

the

transmission.

is

high.

cooling.

sealing

ring

ring.

flanges.

A

new

cable

and

perhaps a

, needed. While

out of gear make

sure there's

If

the

transmission have a helper put the

propeller

needs

professionaI

thrnst,

check the shaft that it isn't stuck

NOTE:

If

the

cable is

using

the

no

passes these

it

in forward and

shaft;

if

attention. If it

to

see

you still have a propeller

or,

if

you

have a

in

the "no

you suspect a major immediately contact your authorized

severe.

plate.

A.

plate.

due

to

and

in

Vibrations,

wrong

excessive

torsional

produces

and

shaft.

marine

transmissioll[acility.

1.

Tighten

2.

Check

the

3.

Detaoh Clearance

Transmission

1.

2.

The

coupling

on

the

pins

and

3.

Inspect A

folding

propeller

1.

Adjust

Refer

to

2.

Check Check

3.

Check

1. inspect engine.

Transmission

2.

1.

Mount a flexible

between

A

higher

2.

Inspect

transmission.

1.

Wrong

Check

2.

1.

Transmission

2.

Check

damping

the

propeller

cover

shift clearance, angnment,

new

linkage

loose,

shift

the

lever

on

the

side

of the transmission to

binding inside

tests,

the

crank

reverse

the

shaft isn't

folding

pitch"

problem

turning,

does

tum but there's

or

feathering

position.

in

WESTERBEKE

Ve,ilicatlon/Remedy

bolt

on

shifting

cable,

reattach

or

replace.

shift

cable

and

should

needs

bolls

coupling

the

propeller. propeller may

be

plate

SHIFT

LEVER

lever

the

damper

Replace

needs

the

transmissIon

stiffness

the

damper

Replace

type

of

cooler,

Inspect

needs

'lignment.

operate

be

0.02

in

professional

are

sheared

Shaft.

Tighten

bolts

as

It

may

be

in

"no

pitch"

until

the

TEXT

cable

length.

adjust

if

necessary.

inspect

flexible

plate

between

if

necessary.

professional

coupling

factor

might

plate

between

if

necessary.

flUid.

Use

ATF.

coolant

professional

Must

be

(0.5mm)

or

necessary.

be

jammed. A variable

position:

lever

AND

See

with

coupling

Check

hoses

within

mechanism

may

transmission

case.

the

engine

while

you

observe

the

transmission

on

the

end

propeller,

your transmission,

dealer or

lever.

the

lever

.

attention.

the

coupling

replace

missing

is

exact

DIAGRAM.

SHIFT

coupling.

the

transmission

attention.

another

with

be

suHiclent.

the

fluid

and

attention.

0.003

an

by

hand.

.

is

slipping

set

screws,

or

damaged.

pitch

mid-position.

LEVER

DIAGRAM.

If

noise

stiftness

factor

and

the

driveshaft.

engine

and

level.

coolant

flow_

in

(O.OBmrri).

be

in

and

no

of

keys,

perSiSts,

and

the

NOTE:

[[you suspect a immediately contact authorized marine

major

problem

your

WESTERBEKE

transmission

facility.

in

your transmission,

dealer or an

~

WESTERBEKE

Engines & Generators

49

HURTH

HBWJZF

TRANSMISSION

TROUBLESHOOTING

Problem

High

fluid

Fluid

on

Fluid

and

Slow

engagement.

No

movement

NOTE:

If

marine

temperature.

transmission

water

you

housing.

mixed;

shifts

of

the

boat.

suspect a major

transmission

hard.,

facility,

·2.

problem

Probable

Fluid

level

1.

2.

Fluid

level

Plugged

3.

4.

No

walerJn

5.

Filter

cill\lged

1.

Loose

screws.

Loose

2.

3.

4.

5.

1.

2.

3.

1.

2-

3.

4.

screw

Loose Loose

fluid

Fluid

level

Damage Selector

Selector Low

fluid

Linkage.

,

Selector Improper Low

fluid

propeller

5.

Prop,ellershaft

6.

'Transmisslon

7.

Engine

in

your

~ause

high

during

low.

or

restricted

'cooling

system.

(If

applicable).

connections.

dipstick.

filter.

high

during

to

fluid

cooler

coritrollinkage. control.

level.

control.

selector

position. level. missing.

broken.

malfunction.

maHunction

..

transmission,

operation.

fluid

coole,

operation.

•.

immediately

1;

·2.

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

1.

2.

3.

1.

2.

,3.

4.

5.

6.

7.

contact

Verllicalion/Remedy

Pump

out

Add Replace

Check Replace

Tighten Tighten, Tighten;

Tighten, Pump

Refer

fluid

fluid.

cooler

cooling

element.

to

replace. replace. replace.

out

Replace

cooler

this

Refer

this

Add

lIuid.

Adjust

(refer

Consult

service

Adjust

(see

Add

fluid.

Replace.

Contact

marlne

Contact

manufacturer.

Contact

marine

your

WESTERBEKE

to

the

maximum

'.'

and

flush

system

and

specification.

fluid

to

the

maximum

and

flush

manual.

this

manual.

station.

this

manual).

repair, repair.

and

mark

water

system,

repair.

'

and

mark

transmission

dealer

and

or

on'

dipstick.

on

dipstick.

hoses.

all

authorized

,

-..Y'

WESTERBEKE

Engines & Generators

50

.

THE

MODEL

FITTING

PRM

120HASABREATHEti,~

ON

THE

TOP

OF

THE

CASEr:::::::!!!!:I

HEWAGE

MODELS

TRANSMISSIONS

aD-AND

NOTE:

drain

plug

this

sealing

120

When

changing

sealing

washer.

.

the'fluid,

washer.

The

take

drain

care

plug

not will

to

leak

lose

without

the

UNDEIJR':C'r."HtE~cUfV~~ER

OF

THE

NOTE:

.INITIAL

Before transmission Dextron

Do

.Run

.the

Model Model

NOTE:

filling

.

Keep

ventlvent

'..

OPERATION

starting

not

the

engine,

PRM PRM

with

CHECKING

Thread the

observe

CHANGING

Change operation, year

or

malee a visual

coupling. dipstick

fluid.

(If

the

drain

sealing

then

reinstall transmission running

the

with

11

or

Dextran

overfill.

engine

re-check

80-1.0

12Q-l.4

Always

fluid.

THE

dipstick

the

fluid

THE.

the

f1l!id

then

when

you

inspection

Push a suction

hole

to

space

allows,

plug

from

washer)

the and

the

engine,

-':'DII'$m:K

.'

GEARCASE

SEALING

holes

clear

and

engine,

au1<>matic

to

warm

clean

Replace

FLUID

level.

the

fully

remove;:

transmission

Ill.

Fill

up

the

fluid

level.

U.S

..

pints

U.S.

pints

area

the

dipstick

LEVEL

into

the

to

the

fluid

(0.6L) (0.8L)

around

case,

TRANSMISSION

for

the

first

time

at'ter

every

250

change

the

bottom

the

and

allow plug properly

shut

operatiog

engine

of

pump

use

the

bottom

the

with

dispose

down

the

of

its

hours

fluid.

shift'

hose

the

housing

transmission

of

the

fluid

to

sealing

of

and

recheck

MOPEL A8MMHEX

'.~

mark

and

the

by

112"

80'(MODEL

WASHER'

unobstructed.

dipstick

fluid

(ATE)

on

.

after

shutting

dipstick

screwing

then

I!nscrew

FLUID

about

25

or

at

Check

for

cables

and

down

through

and

suck

drain).

transmission

drain

into a container,

washer,

the

used

the

Wipe fluid.

HEX

PLUG)

and

the

dipstick.

plug

it

hours

least

leaks

shaft

fluid

PLUG

120

USES

fill

the

down

before

down

it

and

of

once

and

the

out

the

Relilove

(1"

with

down

After

leveL

a

the

A

WARNING:

inglne dipstick

DAILY

OPERATION

o

Check

o

VISually

o

Start idle

o . Shift

NOTE:

from

the

GEAR

The engine must be

seleetiog 120 throttle

.

Too

the

idle

speed

SHIFtiNG

are

ideal

and

A

WARNING:

thr(lttle ahead

LOCKING

Locking required. direction the

position

boat.

WHEN

Rotation

boat

is

being

well

as

operation

(for

charging

on

the

transmission.

Never

is

running.

hole.

This

the

transmission

check

the

engine

to wann

into

transmission

ahead

gear.

Iowan

should

or

for

single

the

gear

the

idle

astern,

When

t(l

idle

and

(lr

astern.

THE

PROPELLER

of

the

propeller

Use

the

gear

of

travel

for

corresponding

UNDER

of

the

propeller

sailed,

the

SAIL

of the

battery),

pull

Hot

fluid

t;(luld

cause

fluid.

gear

shift

in

neutral,

fluid.

speed

gear

and

be

increased.

at

Idle.

Transmission

lever

shift

at

one

shifting

pause

in

.

shaft

shift

lever

this

purpose.

to

.

OR

BEING

without a load,

being

towed

engine

willhave

(lut

the

dipstick

will

splash

from

severe

burns.

linkage

allowing a few

will

damper

PaUse controls,

time.

neutral

by

position

the

direction

and

produce a chattering

plate.

.

in

neutral

models

controlling

gears,

bring

before

an

additional

opposite

Never

put

of

TOWED

such

or

anchored

with

the

propeller

no

detrimental

while

the

transmission.

minutes

In

such

at

noise

cases

befo~e

PRM

80

and

both

the

engine

shifting

brake

is

not

your

the

gear

shift

in

travel

of

the

as

when

lhe

in a river,

as

stopped

effects

Engines & Generators

51

PRM

NEWAGE

TRANSMISSIONS

CONTROL

The

to

the position. cockpit

The shift

internal

the reverse. the shift lever with important adjustment

control

actuating

The

must

level

Those

CABLES

cable

or

rod

shift lever

neutral

position

coincide

stops

with

travel must

for

the

stops

can

the

for

should

with

the

be

lever

be

determined

cable

disconnected.

proper

be

the

of

the

neutral position of

such that

when

engagement of the

MAINTENANCE/SERVICE

Make celtain

fluid

should suffers thoroughly

correct

NEWAGE

world.

the Atlantis

418

Boston TopSfield, Tel:

978-887-0001 Fax:

978-887-5599

the

transmission

become contaminated

major

mechanical

flushed

specifications.

TRANSMISSIONS

Listed here

Marine

Street

MA

Gear

01933

out

are

Supply

fluid

damage,

and

re-filled with

those

Inc.

LTD.

in

MODELS

arranged

lever

operating lever in

shifted

by the

the

at

a right

in

the

neutral

the

lever just strikes

into

by

manually

This

is

changed

water

gearbox

has

United States.

annually.

or

the

fresh

fluid

distributors around

forward is

must

angle

the

this

lever.

moving

an

gear.

gearbox

be

to

the

or

If

80

AND

120

A greater amount of shift lever

tal

and

is

recommended.

shorter,

in

by

proper clutch engagement

turn,

would

generation

slow

NOTE:

cable to

and

clutch

Checkfor

the

lever bracket

WARRANTY

the

NEWAGE Newage Transmissioms will

and

or

24

All and

TRANSMISSIONS

workmanship

months.

PRM

transmissions must

maintained.

TROUBLESHOOTING

See

the

following page.

travel

is

in

no

way

However, if

mean

premature

clutch plate

engagement

proper lever travel and the security

urider

failure.

or

at

least each season.

normal

the

lever

might

be

wear,

excessive

This

would

no

engagement

LTD.

walTants

be

free

fTOm

use

and

service

be

correctly installed,

impeded which,

defects

detrimen-

travel

heat

be

indicated

at

all.

that

for

is

of

the

all

PRM

in

material

a

p~dod

aligned,

Harbor

Marine

Transmission

1402

West

marineview

Everett,

WA

98021

Tel:

425-259-3285

Transmission

223

Southwest

P.O.

Box

Ft.

Lauderdale,

Tel:

954-467-1540

Fax:

954-467-1525

Newage Website:

If a major

dealer walTanty without a NEWAGE distributor (listed dealer.

Marine

21086

Transmissions,

www.Newage-PRM.co.uk

problem should

or a NEWAGE

rights,

first

contacting NEWAGE TRANSMISSIONS LTD.

Drive

33

Court

FL

33335-1086

Limited.

occur,

distributor.

do

not undeltake repair work

above)

contact your WESTERBEKE

To

avoid prejudicing

or your WESTERBEKE

on

the gearbox

'WY'

or

WESTERBEKE

Engines & Generators

52

Excessive

Fluid

Difficulty

noise

needs

in

Escape

of

when

dipstick

No

drive

ahead

Propeller

speed

with

engine

Propeller

speed

with

engine

Excessive

at

low

speeds.

Excessive

operating

Problem·

at

low

at

all

constant

moving

pressure

is

removed.

or

astern.

does

speed

ahead

does

speed

noise

from

noise

throughout

range.

.

PRM

speeds.

topping

lever

control.

from

gearbox

not

increase and

not

increase

in

one

direction

gearbox

NEWAGE

Engine

1.

Defective

1.

2.

Shaft

3.

Prop

off.

astern.

only.

1.

Power

2.

Fluid

1.

Poor

2.

Faulty

1.

Defective past

1.

Mechanical-damper

1.

Shift

1_

Cone/clutch clutch

1.

Engine

1.

2.

TRANSMISSIONS

Probable

misalignment.

out

leak.

installation

all

cable.

Faulty

Defective coupling

Propeller installation

Propeller poorly

CaUse

idle

speed

too

coupling.

of

balance.

too

high.

of

cable.

breather

seals.

plates

idle

adjustment.

matched.

causing

cable

Slippage.

or

clutch

speed

set

input

coupling.

worn/damaged.

shaft

misalignment,

or

hull

flexing.

out

of

balance,

low.

plate

cones.

too

leaks

problem.

Damaged.

low.

Input

faulty

damaged

prop,

TROUBLESHOOTING

.

VerlllcationJReme~y

Increase.ldling

1.

Inspect/replace

1.

Check

2.

Remove,

3.

Compare

1.

Inspect

2.

Check

1.

Replace.

2.

1.

Remove

2.

Unscrew

with Replace

1.

Remove move hand

Remove

1.

shaft Increase

1.

refer coupling

Check

1.

necessary, engine

2.

Remove

diameter

if

necessary.

speed.

coupling

alignment

installation,

solvent -PRM120.

correct

to

and

to

with

check

pitch,

engine

and

transmission

seals,

O-rings,

remoVe

dipstick/clean

vent

assembly

damper

plate.

contrQI

cable

distaQoe.

check

movement.

and

ex.mlne

replace

If

necessary.

idling

speed.

engine

supplier.

if

necassary.

the

alignment

recmy

the

propeller

and

by

or·adjust

balance

mounts

feeler balance

drain

vent

or

Remove

clutch/clutoh

If

of

adjusting

and

if

necessary.

gauge.

and

weight.

data.

plug,

check

sharp

bends

holes -PRM80.

from

top

of

transmission

linkage

not

cable

Adjust

cable

cone

not

cured

propeller

the

engine

check

all

the

by

examine

shims

that

blades

Remove,

the

of

for

fluid

and

turns.

allowing

F-N-R

and

operate

if

necessary

on

appropriate

increasing

and

shaft

coupling.

under

mounts

themselves.

the

pitch,

are

equal

leaks.

and

lever

Idling

replace

the

weight,

and

clean

to

speed,

If

.

rectify

..

by

Difficulty

in

moving

single

lever

control.

D.efective

3.

Worn

1.

Opereting

bearing/bearing.

or

damaged.

control

cable.

3.

1.

Isolate

Check

defective

the

installation

bearing,

ami

remove

eliminate

and

all

replace.

tight

bends

in

the

cable.

~WES'TERBEICE

Engines & Generators

53

12C

AND

120

TWO

ENGINE

SPECIFICATIONS

Engine

Type

Governor

Valve

Mechanism

Combustion Bore & Stroke

Piston

Firing

Direction

Maximum Compression COmpression

Valve

(engine

Dimensions

Inclination

Dry

Fuel

Idle Cruise

Starting

Battery Starting Starter DC Cold

Chamber

Displacement

Order

of

Rotation

Torque

Ratio Pressure

Seat

Angle

Clearance

cold)

Weight

Consumption

Speed

Battery

Capacity

Aid

Motor

No-Load

Current

Cranking

Current

Alternator

Regulator

SPECIFICATIONS

Diesel;"four-cycle,

coated,

vertical

12

Hp @ 3000 Mechanical, Overhead Swirl

chamber

2.99 x 2.76 3B.75

cubic

1 -2

Clockwise, 30

Ib-ft 23:1 39B

psi

Intake

45°

Exhaust

Intake

0.010

Exhaust

Height

Width:

17.22

Length:

Continuous

Temporary 2281bs

1.1

US

at

3600

1000

-1200

2000 -2500

ELECTRICAL

12

Volt, 600 -BOO Glow

plugs,

12

Volt.

100

Amps

125

Amps

12

Volt

Internal

in-line.

rpm

centrifugal

type

inches

when

(4.15

kg-m)

(28

kg/cm')

45°

inches

0.010

inches

19.75

(501.65)

inches

25

inches

14°

25'

(not

(103.4

kgs)

gph

(4.1Iph)

rpm

(approximate) rpm rpm

SYSTEM

(-)

negative

CCA

sheathed

1.2

Kw,

at

11.5

at

10

DC,

50

Amps

regulator,

two-cylinder,

maximum

(76 x 70

(0.635

viewed

at

(0.25)

(437.3)

(635)

to

ground

(Cold

solenoid,

Volts

built

fresh

weight

type

mm)

liters)

from

the

2200

rpm

2BO

rpm

exceed

30

Cranking type

actuator

(3000

(B05

rpm,

into

alternator

water-

front.

min.)

Amps)

shift

rpm,

min)

General

Operating (engine

hot)

Oil

Grade

Oil

Filter

(Pn.

#036920)

Sump

Capacity

(including

General Fuel Injection

Pump

Engine

Timing

(Spill

Timing)

Injection

Nozzle

Air

cleaner

Air

Flow

(engine

combustion)

Lift

Pump

(PN

#039275)

General

Operating

Fresh

Water

(PN#

037015)

Raw

Water

(PN#

033636)

Raw

Water

(measured

discharge

elbow)

System (Fresh

Water)

JS

Model

PRMBO BW7 Propeller Propeller

LUBRICATION

Oil

Pressure

filter)

Pressure

Temperature

Pump

Flow before

into

exhaust

Capacity

2.47:1

2.50:1

2.47:1

Rotation

Shaft

SYSTEM

Pressure

type

by

with

external

15-45

API

Specification

SAE

15W-40

Full

flow,

3.0

U.S.

FUEL

Open

flow,

No.2

diesel In-line 19' ± l'

Static 1991

psi

Throttle Metal 34

cfm

12

volt

COOLING

Fresh controlled

170

-190' F (77 -8B'

Centrifugal

Positive

mechanically-driven

11.1

US

2.9

US

Trochoid

pressure

psi

(1.0-3.1

CF.

(all

season)

paper

element,

q\s

(2.B

liters)

SYSTEM

self-bleeding

(cetane

plunger

type

BTDC

(140

kg/cm2)

type

screen

type-cleanable

(0.96

cmm)

DC

lift

capacity

SYSTEM

water-cooled

with

heat

type,

metal

displacement,

gmp

(42Ipm)

qts

(2.7

liters)

(BOSCH)

block,

TRANSMISSIONS

Right 3/4"

reduction reduction

hand

diameter

(See

reduction

turning -Standard

(minimum)

Transmission

pump,

valve

relief

kg/cm')

CF-4,

CG-4,

spin

on

rating

of

45

of

5'

(1.5

thermostatically-

exchanger

C)

impeller,

rubber

at

3000

pages)

Transmission

gear-driven,

CH-4

or

CI-4

or

higher)

mm)

wet

belt-driven

impeller,

rpm-approx.

~

WESTERBEKE

Engines &

54

Generators

LAY-UP

&

RECOMMISSIONING

GENERAL

Many

owners

rely

on including off-season to

The own check

These during a maintenance

If your provide

engines

accomplish

procedures

lay-up

list

if

procedures

lay-up

you

have

local

assistance.

PROPELLER

The

transmission be opened out of

the

storage

in

severe

strain

the boat

shaft apply not in period of

FRESH

A 50-50 recommended for This

antifreeze, solution

Should amount mixture.

and

cooling

is

has

actually

to

small

use,

time.

WATER

solution

to

more

from

Operate

mixture

system.

LUBRICATION

With

the

engine

oil

sump.

paper

towels

oil

during

When

installing the amount filter. engine. manual). Run sure

of

Fill

(Refer

the there

engine

and

or

for

long

lay-up

which

and

recorrunissioning,

others

do

should

and

needs

any

questions

servicing

SHAfT

and

up

and

the

water

or

the

cradle. The

on

the propeller shaft

taken out

been bent

boats

unless

they

COOLING

of

use

may

require a higher concentration of

depending

make

sure

antifreeze

the

engine

the

of

the

Now

SYSTEM

warm,

Remove

and a plastic

its

removal).

oil

on

the rubber

the

sump

to

the

Use

an

oil

and

are

no

leaks

their

boatyards

generators,

periods

preparation

follow

the

procedures.

afford

also

help

of

your

dealer;

for

of

inactivity.

themselves.

will

allow

or

your engine

familiarize

engine.

regarding

he

will

COUPLING

propeller bolts

moved

or

put

that

have

half couplings

removed

from

land

flexibility

in

the

by

these

are

hauled out of

been

water.

dry

CIRCUIT

antifreeze

in

on the

engine

antifreeze

recheck

and

new

with the correct

SPECIFICATIONS

with

check

and distilled

the

coolant system

the area's winter

antifreeze protection

be

needed,

block

drain

replace

oil

an

..

drain

and add a more

to

ensure a complete

concentration

the

antifreeze

all

the

the oil

bag

around the

filter,

be sure

seallng

API

specification of

for

proper

to

prepare

lay-up

you

lay-up

be

more

when

to

water,

of

the

or

coupling

strains.

for a considerable

lubricating

filter

gasket amount

oil

during

Others

you

to

may

use

protection

you

with

procedures,

than

should

the

boat

and

boat

In

some

This

the

water

at

all

climate.

an

appropriate

concentrated

throughout

solution's

(Place

filter

to

apply a small

at

the

of

section

pressure

their

perform

often

or

is

oil to

oil

craft,

the

prefer

your

them

as

the

call

willing

to

always

is

hauled

during

puts

both,

while

cases,

the

does

not

when

is

times.

Check

adequate.

circulation

the

strength.

from

the

some

catch

the

base of

the

for

your

of

this

CF

or

CG-4.

and

make

a

the

FUEL

SYSTEM

Top

off

your

fuel

tanks

such

as

BioBor

at

added condition used

are separator primary

Change fuel

system,

for

5 -

10 system. the

fuel needed. allow

movement

equipment

RAW

WATER

Close the hose

from gallon bucket check

the

engine

any

zinc

anode

Start the fresh

water

stop the

solution protection in

Start the through the

engine.

water circuit

as

providing

Remove

antifreeze mixture will

Examine the

a cover

until

recorrunissioning,

INTAKE

Place a clean opeuing of

the

shove recorrunissioning,

may

you note

to

exhaust port

and

Diesel Kleen + Cetane Boost should be

this

time

to

the

fuel.

Care

compatible

used

in

the

filter

and

clean

the

fuel

filter

as

needed.

minutes Check system

Operating

on

for

during

of

the

to

any

the

engine.

COOLING

through-hull

the

seacock.

of

clean

zinc

anode

and

clean

debris

from

is

located.

engine

and

through

engine

and

slightly

the

gasket.

stronger

your

area.

engine

and

raw

water

This

antifreeze mixture should protect

from

freezing

corrosion

the

impeller

impeller.

Do

MANIFOLD

cloth,

the

intake

cloth out of

and

need assistance of

remove

the cloth

can

be blocked

with

No.2

Diesel

fuel.

Fuel additives

control

should

with

the

system.

the

elements

Start

make

leaks this

engine

the

treated

bacterial growth

be

taken

primary

Change

separator

the

sure

that

servicing,

on

for

fuel

the

engine

no

air

may

5 -

through

sediment

and

to

that

the

additives

fuel

filter/water

the element in

bowl.

engine and bleed

and

allow

is

left

in

the

have been created in correcting them 10

minutes

the

injection

will

CIRCUIT

seacock.

Place

fresh

found

or

replace

inside the heat exchanger where

Clean

allow

the

refill

allow

system.

protection.

from

Acquire a replacement,

not

replace

AND

lightly

manifold

sight.

an

Remove

the

end

water.

Before

in

the

primary

it

as

the

raw

the

raw

water

system.

accompany

but

When

the

bucket with

than

needed

all

of

Once

during

your

the

replace

this

the

raw

impeller

THRU-HULL

soaked

in

to

block

(If

it

is

attempt

prior

is

the

servicing

to start-up.

in

the same

the

raw

of

this

hose

starting the engine,

heat

exchanger

required, and

water

strainer.

pump

to

the bucket is

an

antifreeze

for

winter

mixture the bucket

water

it,

the

to

winter lay-up,

pump

so

catch

it

if

(into

cover and

EXHAUST

lubricating

the

opening.

not

visible

made to start

dealer).

The

thru-hull

manner.

water intake

freeze

be

is

in a bucket).

needed,

oil,

at

your

it

to

fuel

as

help

into a

also

the

draw

empty,

drawn empty, the

raw

as

(some

the

pump)

gasket.

in

Do

the

engine,

Make

the

run

five

on

clean

the

stop

well

and

the

not

a

A

CAUTION:

in

the

sump

combustion

chemicals internal

paris.

Do

not

over

the

depOSits

which

can

leave

the

lay-up

period.

combine

reduce

the

engine's

~ubricating

to

produce

-life

of

old

engine

oil

and

harmful

your

engine's

I~--'WESTERBEKE

--,

Ergines

& Generators

55

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication if battery

the

connections

Cylinder

If WESTERBEKE with

each

good crankshaft plugs washers

Intake

Clean cloth block

through-hull exhaust to

Cylinder

With

intake, stalling

cylinders

NDTE:

plugs and

Re-install the high

access

connections

starter.

you

anticipate a

SAE

cylinder

quantity

or

the

lightly

any

start-up!

the

At

tension

Motor

and

cleaaing of

to

the

starter

Take

care

removed

Lubrication

recommends

#40

oil.

or

the

of

oil

by

hand injectors. that

may

be

Manifold

filter

screen

soaked

opening.

Lubrication

engine

running,

the

..

spring commissioning,

rotate

the

spar.k

leads fully onto each spark plug.

Batteries

If

batteries

make

to

prevent them

batteries will

subjected

batteries

environment.

A

are

to

be

sure

that

they

from

not

remain

to

severe

and

store

WARNING:

highly·explosive

arcing

or a lighted

smoke

or

allow serviced. to

Shut

prevent

electrical

Transmission

Check

or

change

off

grime

aad

grease

the

coupling coating. additional

and

Check

that

iilforrnation,

the

starter drive

permits

are

in

from

its

easy

removal.

shut off before attempting

properly replacing aay electrical

the

starter.

[Diesel]

long

lay-up period

To

do

this, either remove

fuel

injector,

into

each

slowly

two

Make

sure you

needed

for

(12

months

you

coat the engine

which ever is

cylinder.

revolutions. Re-install the

have

the

injectors

Then rotate

available aay

[Gasoline]

in

the

flame

arrester,

in

lube

oil

around

the

flame

Also

place aa oil-soaked cloth

port,

Make a

note

to remove

[Gasoline]

spray

the

fogging

engine.

This will

engine

by

plugs,

tighten properly and reconnect

left

on board during the lay-up

are

fully

freezing.

fully

environmental

them

in a warmer,

Lead

acid

gas,

which

cigarette,

an

open

flame

off

all

electrical

arcing

[Propulsion

the

fluid

in

aad touch

the

output

the

transmission vent refer

lubricate,

remove

hand

two

charged,

If

there

charged,

conditions,

batteries

can

be

cigar,

near

equipment

during

Engine]

the

transmission

up

any

flange

with

to

the

TRANSMISSION

and clean

complete

aad will remain

is

any

or that

more

emit

ignited

or

pipe.

the

servicing.

unpainted

an

is

-,

pinion

is

advisable,

Make

sure

to

remove

or

more)

cylinders

the

glow

plug

easiest.

Squirt

the

engine

sealing

return

line

..

aad place a

oil

into

the

doubt that

they

remove

compatible

clean

arrester

in

the

cloths

the

open

valves

the

spark

revolutions.

period,

that

will

the

hydrogen,

by

electrical

Do

not

battery

being

in

the

vicinity

as

required

areas.

anti-corrosion

open.

For

SECTION.

the

for

glow

to

prior

aad

the

way,

the

be

a

Wipe

Protect

Spare

Lay-up Westerbeke

Parts

time

or

coolant hoses

kit

and

order items

the

during

SPARE

PARTS

provides a good

engine

lay-up,

Recommissioning

The

recommissioning of

seasonal

those described in

a

tion regarding preparation However, counteracted before

1.

2.

3. Reinstall

4.

5.

'

lay-up generally

some

Remove Remove

discard removed Install

lay-up, terminals Check

A

and

batteries can

the

and

to

CAUTION:

eye

protection

emit

be

ignited

cigarette,

flame

near electrical arcing

Remove proper tightness [gasoline

Check circuit that solution from engine short period of time

6.

equipment

during

the and

it

is

advisable, service, heat

exchanger and clear

area.

Start

the engine

in

the

PREPARATIONS

maaual.

opportunity

to

see if external

need

replacement.

not

on

hand,

or

such

as

filters

and

section of

of

oil-soaked

raw

old

during

raw water

the

batteries

reconnect

are

make sure

this

your

follows

the

PREPARATIONS

for

the

lay-up

starting

gasket.

lay-up

clean

Wear

the

cloths

water

pump

Install

(or a replacement,

pump

that the

and

that

the batteries

rubber

when

servicing

manual.

Westerbeke

starting

procedures

engine.

cover

were

battery

the

gloves, a rubber

hydrogen, a highly

by

cigar,

the

battery

electrical

or

pipe.

Do

being

in

the

arcing

not

serviced.

vicinity

servicing.

the spark

plugs,

wipe cleaa,

J.

condition of the zinc

clean

or

replace the

not necessary

the

put into operation, the

as

either

to

inspect the area

to

raw

water

with

an

end

in

accordaace

flush

no

of season

where

any and

FOR

to

inspect your

items

such

Check

your

replace

the

from

cover

the

those

zinc

anodes.

engine

same

procedures

FOR

STARTING sec-

aad

normal

will

need to

the intake manifold.

and

gasket

raw

water

if required),

with a new

removed

cables,

connections

during

making

are

fully charged.

batteries.

explosive

or a lighted

smoke

or

allow

Shut

to

prevllnt

re-gap,

anode

in

the

anode

as

needed.

the

antifreeze/fresh water

coolant

system.

system

adverse

the all

with

procedures

STARTING

will affects. or

recommissioning

zinc

as drive belts

basic

spares

items used

Refer

to

the

after

a

as

starts,

be

and

pump impeller

cover

gasket.

the

sure

the

are

tight.

apron,

Lead

acid

gas,

which

an

open

off

all

eillctrical

and install

raw water

Note

When

the

self-flush

It

is

located

debris

section of

in

is

in

from

described

this

that

to

a

the

"tIY'

WESTERBEKE

~ngines

56

& Generators

COMPONENT

TORQUE

FHB

(M-KG)

SPECIFICATIONS

COMPONENT

FHB

(M-KG)

Alternator Back Connecting Coolant Coolant

.

CoolantTemperature

Bracket

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

Plate

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

Rod

Cap

Pump

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

Pump

Pulley

CoolantTemperature Crankshaft

'Cylinder

M8

M10 Cylinder Engine Exhaust Fuel

M30 Flywheel Glow Glow

Governor

Idler Injection Injection Injection Injection

Injection Lock

Pulley

Nut,

Head

Bolts

(12)

Bolts

1,

2, 3 ................

(14)

Bolts

4 -

Head

Cover

Mounts

Solenoid

Plug, Plug

M4

(7)

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

Manifold

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

Locknut

(36)

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

bolt

M1 0 (17)

M10

(12)

Lead

Wire

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

Assembly

Relief

Plunger

Assembly

Taper

Plug

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

Gear

Thrust

Plate

Nozzle

to

Body

Pipe

Flare

NuL

Pipe

Nut,

M12

Pump

Delivery

M16

(17)

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

Pump

Nut

Drive

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

27 -38 24 -35

M8

(14)

......

23 -28.2 12 -17

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

Sender

Switch

M16

........

..........

(24)

..72 -86

12 -17 9 -

9 -

(wet)

14 -21

11

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

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

54 -61 2 - 3 23 -34

..20 -24

28.9

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

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

Fitting

61 -68 11 -14.5

Nut,

.

.........

28.9 -36.2

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

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

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

(17)

........

Valve

Holder

Gear

(3.8 -5.3) (3.3 -4.8)

(3.2 -3.5) (1.6 -2.4) (1.6 -2.4)

13

(1.2 -1.8)

13

(1.2 -1.8)

(10 -12)

(2.0 -3.0l (7.8 -8.5

(0.3 -0.45)

(3.2 -4.7) (2.7 -3.3)

..

36.2 (8.5 -9.5)

(1.5 -2.0)

0.7 -1.0

11 -23

15 -23

(0.1 -0.15)

(1.5 -2.2)

(2.2 -3.2)

25.3 -36.2 18 -22 18 -25

(2.5 -3.0) (2.5 -3.5)

25.3 -28.2 29 -51

(4.0 -7.0)

(4.0 -5.0)

(3.5 -4.0)

(3.5 -3.9)

.

Injection

M10

(14) Injectors Intake

Manifold

Main

Bearing

.

Nozzle

Holder

M20

(21) Nozzle

Retaining

M16

(21)

Nozzle

Union

M12

(17)

Oil

Drain

Oil

Filter

M20

(17)

Oil

Pan

Bolts

Oil

Pressure

Oil

Pressure

Oil

Relief

Rear

Oil

Rocker

Arm

Rocker

Arm

Rocker

Cover

Rocker

Shaft

M8

(12) Thermostat Timing

Gear

Torque

Spring

Water

Temperature

M16

Pump

Hollow

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

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

Cap

(fitting

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

Screw

7.2 -10.8 36 -38

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

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

to

engine),

12 -17 36 -38

36.1

Nut,

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

Color

Fixing

Nut,

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

Hose

Plug

M18

(19)

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

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

Sender

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

Switch

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

Plug

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

Seal

Cap

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

Assembly Cover

Nut,

Hold-down

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

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

M6

(10)

Bolt,

25.3 -28.9

18.0 -21.6

.....

:36.1 -43.3

7.9 -9,4 12 -17 9 9 -

28.9 -36.1 11 -14 11 -15

1.8 -2.9

..........

3.6 -5.0

13 13

...................................... 1 0.8 -15.9

Housing

(17)

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

Case

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

Set

Locknut

Gauge

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

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

Joint

6 - 8 12 -17 6 - 9

14.4 -21.6

.

(1.0 -1.5) (5.0 -6.0) (1.6 -2.4) (5.0 -5.5)

-43.3

(5.0

(3.5 -4.0)

(2.5 (5.0 -6.0)

(1.1 -1.3)

(1.6 -2.3) (1.2 -1.8) (1.2 -1.8)

(4.0 -5.0) (1.5 -2.0) (1.5 -2.2)

(0.25 -0.40) (0.5 -0.7)

(1.5 -2.2)

(0.8

-

1.1)

(1.6 -2.4).

(0.8 -1.2)

(4.0 -5.0)

-6.0)

-3.0)

NOTE:

Hardware listed

Flywheel

'(wet)

ai/film wiped on them before

have not no

oil

Bolt,

M10

indicates Metric,

(17)

indicates 17mm across the flats

indicates that the bolts

been

removed

is

needed,

is

metric, with values given

M1 0 (17)

10mm

(if

removed) are to have a thin

they are retorqued.Ifthe bolts

and need only

thread diameter;

to

of

be

as

follows:

the bolt head.

retorqued,

-.N"

then

WES~RBEKE

Engines

~Generators

57

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions of

an inch

1/64 1/32 0.03125

3/64

1/16 0.0625 1.58750 5/64 0.078125 3/32

7/64 0.109375

1/8 9/64 0.140625 5/32

11/64 0.171875

3/16 0.1875

13/64

7/32

15/64 0.234375

1/4

17/64

9/32

19/64

5/16

21/64 0.328125

11/32 23/64 0.359375

3/8 25/64 13/32 27/64 0.421875

7116 29/64 0.453125 11.50937 15/32 0.46875 31/64 0.484375 12.30312

1/2

Decimal (in.)

.

0.015625

0.046875

0.09375

0.125

0.15625

0.203125

0.21875

0.250 6.35000

0.265625

0.28125

0.296875 7.54062 51/64 0.796875 20.24062

0.3125 7.93750 13/16

0.34375

0.375 9.52500

0.390625

0.40625

0.4375 11.11250 15/16 0.9375

0.500

Metric (mm)

Fractions of

an

inch

0.39688

0.79375

1.19062

1.98437 37/64 0.578125 14.68437

2.38125 19/32 0.59375

2.77812 39/64 0.609375

3.175 5/8 0.625

3.57187 41/64 0.640625 16.27187

3.96875 21/32 0.65625 16.66875

4.36562 43/64

4.76250 11/16 0.6875

5.15937

5.55625 23/32 0.71875 18.25625

5.95312 47/64

. 6.74687

7.14375 25/32 0.78125

8.33437 53/64

8.73125 27/32 0.84375

9.12812 55/64

9.92187 57/64

10.31875 29/32 0.90625

10.71562

11.90625

12.70000

33/64 0.515625

17/32 0.53125 13.49375

35/64 0.546875

9/16 0.5625

45/64

3/4 0.750

49/64

7/8

59/64 .

61/64 31/32 63164

1 1.00

Decimal (in.) Metric (mm)

13.09687

13.89062

.14.28750

15.08125

15.47812

15.87500

0.671875 17.06562

'"

0.703125' 17.85937

0.734375 18.65312

0.765625 19.44687

0.8125 20.63750

. 0.828125 21.03437

0.859375 21.82812

0.875 22.22500

0.890625 22.62187

0.921875 23.41562

0.953125

0.96875 24.60625

0.984375.

.

17.46250

19.05000

19.84375

21.43125

23.01875

23.81250

24.20937

25.00312

25.40000

Ermines & Generators

58

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(tt) X .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

VOLUME

Cubic

Inches

(in') x 16.387 = Cubic

Imperial Imperial Imperial

Imperial Imperial Fluid US US US

Pints

(IMP

Quarts

(IMP

Galions

Quarts

(IMP

Galions

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

pt) x .473 = Liters(L) x 2.113 = Pints Quarts Gallons

(US

qt) x .946 = Liters

(US

MASS-WEIGHT

Ounces Pounds

(oz) x 28.35 = Grams

(Ib) x .454·=

PRESSURE

Pounds Inches Inches

Inches Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

Centim~ters

pt) x .568 = Liters

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt)

x1.201 = US

(IMP

gal) x 1.201 = US

gal) ~ 3.785 = Liters

(g) x .035 = Ounces

Kilograms

In

(psi) x 6.895 = Kllopascals

(Hg) x .4912 = psi x 2.036 = Hg

(Hg) x 3.377 = Kilopascals (H,O) x .07355 = Inches (H,O) x .03613 = psi x 27.684 = H,O

(H,O) x .248 = Kilopascals

(L) x 1.76 = IMP

Quarts

Gallons

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kg) x 2.205 = Pounds

x

.061

(L)

x.88 = IMP

(L) x .22 = IMP

(US

qt).x

(US

(kPa) x .145 = psi

(kPa) x .2961 = Hg

of

Mercuryx

(kPa) x 4.026 = H,O

.

=in'

pt

qt

gal

.833 = IMP

gal) x .833 = IMP

13.783 = H,O

qt

gal

TORQUE

Pounds-Force Pounds-Force

VELOCITY

Miles

Per

Inches Feet

.

Hour

(MPH) x 1.609=

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree Degree

Fahrenheit

Celsius

(OC) = (OF -32) x .56

(in-I

b) x .113 = Newton

(tt-Ib) x 1.356 = Newton

Kilometers

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers

(Km/L) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Km/L) x 2.352 = US

(OF) = (OC X 1.8) + 32

-.,.y'

WESTERBEKE

Englnf!s & Generators

MPG

Meters

Per

Hour

Per

MPG

(Nm) x 8.85

(Nm) x .738 = tt-Ib

(KPH) x .621 = MPH

.Liter

Per

Liter

=in-Ib

(Km/L)

59

SUGGESTED

SPARE

PARTS

Carry

Only

Genuine

Westerbeke

Spare

Parts

. . ' 0

•

'"'

Jr;~

{::

HARDWARE

.

0,

'.

KIT

WESTERI3EKE

ENGINE

.

AND A GALLON

WESTERBEKE each

packaged

Kit

"An

includes

Kit

"B"

is

A

Impeller

lIeat

.

Fuel

Oil

.'

DrlveBelt ZlncAnodes

in a

'for

more.

Kit.

Exchanger

Filter

also

offers

rugged

the

basic

extensive

Kit

with

two

hinged

spares.

off-shore

Gasket

Gasket' •

Spare

toolbox.

OIL

Pints

Kits,

cruising.

:

(YOUR

BRAND)

OF

PREMIXED

SP.ARE

.

-..yo

PARTS

WESTERBEKE

Engines. ~ Generators

60

CARRYING

FOR

Alii

OIL

COOLANT.

.•..

ENOUGH

CHANGE

"'~

SPARE

(5

.

......

OTS.)

.

BKit

Impdller Kit Water

Primp

; Thermostat

Zinc

Anodes Complete Heat

Exchanger

.Injector

Fuel Filter

Oil·

Filter

Drive

Belt'

Repair Kit

Kit

Gask,et

Gasket

with

Gasket

Kit

~

WESTERBEKE

Engines & Generators

1158·2/2011

Westerbeke 12C- TWO, 12D-TWO Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual