Westerbeke 80N4, 110T4, 120N6, 170T6 Operator's Manual

OPERATORS

MANUAL

80N4/11

OT

MARINE

4 -120N6/170T6

01

PUBLICATION NO. 045139

FIRST EDITION

JULY 2000

L

ENGINES

WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL

150

JOHN

AIIT'-AIITAIIT

NMMA

..

UWW

HANCOCK ROAD, TAUNTON, MA 02780-7319

Member National Marine Manufacturers Association

PARK

A

WARNING

Exhaust colorless unconsciousness exposure

-

-Nausea

-Headache

-

IF GET seek

until

gasses

gas.

can

Dizziness

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

contain

Carbon

include:

and

Sleepiness

THE

attention.

been

Carbon

Monoxide

and

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

Monoxide.

is

poisonous

Symptoms

-

- Inability

IMMEDIATELY. down

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They

obtainable

of

Throbbing

Muscular

Vomiting

to

ANY

the

unit

DECAL

and

near

also

MONOXIDE

are

inexpensive

at

your

Carbon

Twitching

OF

your

quarters

an

odorless

and

can Monoxide

in

Temples

Think

Coherently

THESE

SYMPTOMS.

If

symptoms

and

do

not

is

provided

should

engine

recommends

DETECTORS

of

and

local

marine

and

cause

persist.

restart

be

fixed

or

generator.

your

easily

by

to

a

installing in

the

vessel. store.

CALIFORNIA

PROPOSITION

Diesel

engine

of

its

constituents

the

State

cancer,

birth

reproductive

exhaust

of

California

defects,

65

WARNING

and

some

are

known

to

cause

and

other

harm.

to

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety by failure Know when dangerous conditions exist necessary precautions to protect yourself, and

your

The following safety instructions are in compliance with the American Boat

PREVENT

A

WARNING:

while

engine

power.

• Do not operate this machinery without electrical enclosures and covers

• Shut off electrical power before accessing electrical equipment.

• Use insulated mats whenever working equipment.

• Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working on electrical equipment.

• Do not connect utility shore power to vessel's AC

circuits, except through a ship-to-shore double throw transfer switch. Damage to vessel's AC generator may result

• Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together.

PREVENT

A

WARNING:

exhaust

very

hot!

• Always check the engine coolant level at the coolant recovery tank.

A

WARNING:

•

In

case

before touching the engine

manual

to

follow

machinery.

and

ELECTRIC

is

Lethal

voltage

if

this procedure is not followed.

BURNS -HOT

system

of

an engine overheat, allow the engine to cool

carefully. Most accidents are caused

fundamental

Yacht Council (ABYC) standards.

rules

and

precautions.

and

talre

your

SHOCK

Do

not

touch

AC

electrical

running,

or

when

is

present

in

place.

connected

at

these

connections!

on

electrical

ENGINE

Do

not

touch

hot

engine

parts

components. A running

Steam

can

cause

or

checking the coolant.

engine

injury

or

the

personnel,

connections to

shore

or

gets

death!

PREVENT

A

• Prevent flash fires. sparks to occur near the carburetor, fuel line, filter, fuel

pump, or other potential sources of spilled fuel or fuel vapors. removing the fuel line, carburetor, or fuel filters.

• Do not operate with a Coast Guard Approved flame

arrester removed. Backfire can cause severe injury or death.

• Do not operate with the air cleaner/silencer removed.

Backfire can cause severe injury or death.

• Do not smoke

fuel system. Keep the compartment and the engine/generator clean and free

fire.

• Be aware - diesel fuel will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. after fueling. Check below for fumes/vapor before running

the blower. Run the blower for four minutes before starting your engine.

• All

handling and storing fuels. Store fuel area away from spark-producing equipment and out reach

• Do not

• Shut off the fuel service valve at the fuel system. Take care spill. sources of Ensure proper ventilation exists when servicing the system.

• Do not alter or modify the fuel system.

• Be sure all fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened and free of leaks.

• Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the

BURNS -FIRE

WARNING:

Use a suitable container to catch all fuel when

Wipe up all spilled fuel and engine oil.

Fire

can

cause

injury

or

death!

Do

not smoke or permit flames or

or

permit flames or sparks to occur near the

of

debris to minimize the chances of

BURNS -EXPLOSION

WARNING:

or

death!

fuel

vapors are highly explosive. Use extreme care when

of

children.

fill

DO NOT allow any smoking, open flames.

for all applications encountered

Explosions

the fuel tank(s) while the engine

fire

near the fuel system or engine when servicing.

from

fuel

vapors

Open and ventilate cabin

in

a well-ventilated

the

engine when servicing

in

catching any fuel that might

NFPA are appropriate

in

this environment.

can

is

running.

cause

of

or

other

fuel

the

Engines

& Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect it last.

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are reinstaIled before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke

being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or equipment servicing.

• Never connect the negative

(+) connection terminal

the battery condition Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumu-

lation the battery charger connections while the battery charged.

• Avoid contacting the terminals with tools, etc., to prevent burns or sparks that could cause an explosion. Remove wristwatch, rings, and the battery.

• Always turn the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last when servicing the battery.

BATTERY

A

WARNING:

severe

STARTING

Accidental

starting

can

cause

of

the engine before

EXPLOSION

Battery

or

aIlow

by

lit tobacco products. Shut off all electrical

in

the vicinity to prevent electrical arcing during

of

explosive gases.

explosion

an

open flame near the battery

(-)

of

the starter solenoid. Do not test

by

shorting the terminals together.

To

any

other jewelry before handling

can

cause

battery cable to the positive

avoid sparks, do not disturb

ACID

injury

Sulphuric

or

death!

acid

in

batteries

injury

is

can

being

cause

TOXIC

• Ensure that the exhaust system

• Be sure the unit and its surroundings are weIl ventilated.

.•

• For additional information refer to ABYC T-22 (educa-

• Do not use copper tubing

• Do not instaIl exhaust outlet where exhaust can be drawn

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists.

attention to the manifold, water injection elbow, and

exhaust pipe nipple.

In

addition to routine inspection instaIl a carbon monoxide detector. Consult your boat builder or dealer for instaIlation

tional information on Carbon Monoxide).

A

WARNING:

odorless nausea

• Although diesel engine exhaust gases are not as toxic as

AVOID

gas.

or

fumes can rapidly destroy copper tubing tems. Exhaust sulfur causes rapid deterioration tubing resulting

through portholes, vents, or air conditioners. If the engine exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the flow

of

exhaust. Avoid overloading the craft.

exhaust fumes from gasoline engines, carbon monoxide

is

present

gas toms or signs are:

Vomiting

Dizziness

Throbbing

Muscular twitching Intense headache Weakness and sleepiness

MOVING

GASES

Carbon

Inhalation

death!

in

diesel exhaust fumes. Some

of

carbon monoxide inhalation or poisoning

in

monoxide

Carbon

monoxide

produces

in

exhaust/water leakage.

temples

(CO)

is

adequate

of

the exhaust system,

of

approved detectors.

(CO)

flu-like

diesel exhaust systems. Diesel

is a deadly

is

in

PARTS

gas!

to

expel gases

Pay close

an

invisible

symptoms,

exhaust sys-

of

copper

of

the symp-

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps.

is

destructive. If

A

WARNING:

or

death!

• Do not service the engine/generator while situation arises

Engines & Generators

ii

Rotating

in

which it

parts

can

cause

injury

it

is

running. If a

is

absolutely necessary to make

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets. shirts, sleeves. rings. necklaces or bracelets that could be caught moving parts.

• Make sure all attaching hardware Keep protective shields and guards in their respective places at all times.

• Do not check fluid levels or the drive belts' tension while

is

the engine/generator

• Stay clear when the engine

be

HAZARDOUS

A

of

the drive shaft and the transmission coupling

caught

in

these rotating parts.

NOISE

WARNING:

operating.

is

running; hair and clothing can easily

High

noise

is

properly tightened.

levels

can

cause

in

hearing

loss!

• Never operate a generator without its muffler installed.

• Do not run

removed.

• Do not run engines or generators for long periods with their enclosures open.

A

WARNING:

are

mentally

an

engine with the air intake (silencer)

00

not

work

on

machinery

or

physically

incapaCitated

by

when

you

fatigue!

ABYC, INSTALLING

NFPA

AND

GASOLINE

USCG

PUBLICATIONS

AND

DIESEL

FOR

ENGINES

AND

GENERATORS

Read the following ABYC. NFPA and USCG publications for safety codes and standards. Follow their recommendations when installing your WESTERBEKE engine/generator.

ABYC (American Boat and Yacht Council)

"Safety Standards for Small Craft"

From:

Order

ABYC 3069 Solomon's Island Rd. Edgewater, MD 21037

NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Craft"

From:

Order

NFPA

1 Batterymarch Park

P.O.

Box 9101

Quincy, MA

USCG (United "USCG 33CFR183"

From:

Order

U.S. Government Printing Office

. Washington, D.C. 20404

02269-9101

States Coast Guard)

OPERATORS

Many

of

in

your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully. maintain your equipment, and follow all safety procedures.

GASOLINE

MANUAL

the preceding safety tips and warnings are repeated

ENGINE

AND

GENERATOR

INSTALLATIONS

Preparations to install a gasoline engine begin with a thorough examination Yacht Council's (ABYC) standards. These standards are from a combination

Sections H-2 Ventilation

H-24 Gasoline fuel systems P-l Exhaust systems

P-4 Inboard engines E-9 DC Electrical systems

All installations must comply with the Federal Code Regulations (FCR).

of

sources including the USCG and the NFPA.

of

the ABYC standards

or

generator should

of

the American Boat and

of

particular interest are:

of

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict

attention be paid to the following information:

CODES

Federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow or will be below the vessel's waterline, provisions must be made to install a

break in the raw water supply hose to the exhaust elbow. This hose must be looped a minimum

the exhaust

raw water damage to the engine

If

you have any doubt about the position

to the vessel's waterline under the vessel's various operating conditions,

siphon-break.

NOTE:

operation. engine damage.

EXHAUST

The exhaust hose must be certified for marine use. The system must be designed prevent water from entering the exhaust under any sea conditions and at any angle of

of

20" above the vessel's waterline. Failure to

manifold

A siphon-break

Failure

Consult

SYSTEM

the vessels hull.

A

detailed

diesel,

engines

use

injection port

requires

to

properly maintain a siphon-break can result

the

siphon-break manufacturer for proper

40

page

Marine

and

generators,

is

at

or below the load waterline will result in

and

possible flooding

of

the water-injected exhaust elbow relative

periodic inspection and cleaning

Installation

Manual

is

available

of

covering

from

a siphon-break when

the boat.

to

in

gasoline

your

WESTERBEKE

dealer.

is

close to

siphon-

instaU a

ensure

proper

catastrophic

maintenance.

and

to

Engines & Generators

iv

TABLE

Parts

Identification

Introduction .............................................................

Warranty

Serial Number Location ................................. ..4

Admiral Fuel,

Oil Pressure ...................................................... 6

Preparations

Procedures ........................................

Control

Engine

Oil

for Starting/Stopping Warning Engine The

Starting the Engine .........................................

Maintenance Cooling

Thermostat ......................................................

Raw Water Pump ............................................ 16

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

Air Intake Filter ..............................................

Fuel

Fuel Lift

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

Fuel PumplFuel Bleeding ............................... 20

Engine

Oil Change .................... : .................................

Remote Oil Filter ............................................ 22

Water DC

Alternator Troubleshooting ............................ 24

Battery ............................................................ 25

Glow

Lights,

Break-In

Daily

Routine

Schedule .....................................

System

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

Pump ................................................ 19

Lubricating

Heater

Electrical

Plugs ..................................................... 26

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

Panel

Alarms

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

and

Coolant

Initial

Procedure

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

Start-Up

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

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

and

Circuit

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

Breaker

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

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

Oil

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

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

System

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

......

.........

OF

2 3

.3

.5

6

7

8 9

10

.

11 11

12

. 14

15

17 18

.

19

21 21

23

.24

CONTENTS

""

W

Engine

Tachometer

Engine

Hurth

Borg

Transmission Lay-up Metric Specifications Specifications Specifications Specifications Suggested

0"

IFing

lagrams

Troubleshooting

................ ; ...............................

...

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

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

Adjustments

Drive Belt Adjustment .................................... 32

Fuel Injectors ................................................. 32

Testing Engine Compression .......................... 33

Testing Oil Pressure ........................................ 33

Valve Clearance Adjustment ......................... .34

Injection Timing ............................................ 34

Transmissions

Changing Fluid ............................................... 37

Maintenance .................................................. 37

Cable Connections .......................................... 38

Shaft Couplings .............................................. 38

Warner

Changing Fluid ..............................................

Maintenance ..................................................

Transmission

Troubleshooting

and

Recommissioning

Conversions

Spares

...

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

.....

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

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

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

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

80N4

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

11

OT4

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

120N6

170T6

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

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

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

27

29 31

32

36

39

.40

41

.42

.44

.46

..48

.49

50

51 52

Engines & Generators

1

DC

ALTERNATOR

PARTS

IDENTIFICATION

ID

NAME

PLATE

MODEL

110T4

ILLUSTRATED

COVER

FRONT

RAW

WATER

OIL

DRAIN

HOSE

MANIFOLD

COOLANT

PRESSURE

FILL

CAP

LEFT

SIDE

OIL

FILL

EXHAUST

-~----;;I--'---

STARTER

MOTOR

THERMOSTAT ASSEMBLY

ELBOW

MANIFOLD

HEAT EXCHANGER

TRANSMISSION

FLUID

DIPSTICK

CONNECTION SIPHON

BREAK

TURBOCHARGER

AIR

&

FILTER

TRANSMISSION OIL

COOLER

REAR

INTAKE/"

//.

OIL

GALLERY

OIL

FILTER

RIGHT

OIL

SIDE

INJECTION PUMP

FUEL

MOUNT

DIPSTICK

FUEL

BLE

FILTER

PRIMING

PUMP

Engines & Generators

2

INTRODUCTION

These high perfonnance marine engines are products WESTERBEKE's long years technology. dependable perfonnance Thank you for selecting WESTERBEKE.

In

order to get the full use and benefit from your generator,

it

is

important that you operate and maintain it correctly. This manual manual carefully and observe all the safety precautions throughout. Should your engine require servicing, contact your nearest WESTERBEKE dealer for assistance.

This provided and a technical manual is available from your WESTERBEKE dealer. equipment, contact your WESTERBEKE dealer for WESTERBEKE'S installation manual.

WARRANTY

Your WESTERBEKE Warranty is included folder. If. after fonn you have not received a customer identification card registering your warranty, please contact the factory in writing with model infonnation, including the unit's serial number and commission date.

Customer

We

take great pride in the superior durability and

is

designed to help you do this. Please read this

is

your operators manual. A parts catalog is also

PROCEDURES

60

days

Identification

of

experience and advanced

of

our engines and generators.

If

you are planning to install this

in

of

submitting the Warranty Registry

Card

of

a separate

l"WV"JWESTERBEKE

I

Customer Identification

USA

Ser.

I

OWNER

#UOOOO-E702

MR. WESTERBEKE MAIN STREET HOMETOWN, Model80N4 Expires

2151200

PRODUCT

Product software, (technical data, parts lists, manuals, brochures and catalogs), provided from sources other than WESTERBEKE are not within WESTERBEKE's control.

WESTERBEKE CANNOT CONTENT RANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS BE

LIABLE FOR INCURRED IN CONNECTION WITH OF

THE FURNISHING OR

WESTERBEKE customers should keep span between printings and the unavoidable existence

product software. The product software provided with . WESTERBEKE products, whether from WESTERBEKE or other suppliers, must not and cannot be relied upon exclu-

sively as the definitive authority on the respective product. It

not only makes good sense but

representatives

be consulted to detennine the accuracy and currentness

product software

NOTES,

As this manual takes you through the operating procedures.

maintenance schedules, and troubleshooting

engine, critical infonnation will be highlighted

CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

A

observed, your

SOFTWARE

BE

RESPONSIBLE FOR THE

OF

SUCH

SOFTWARE,

THEREOF

ANY

TYPE

USE

of

WESTERBEKE product software

of

WESTERBEKE

being consulted by the customer.

CAUTIONS

An

operating procedure essential to note.

CAUTION:

can

AND

Procedures

result

in

the

WARNINGS

engine.

MAKES

AND

WILL

OF

DAMAGE

OF

SUCH

of

earlier WESTERBEKE

is

imperative that appropriate

or

the supplier

which,

if

damage

NO

IN

NO

OR INJURY

OR

ARISING

SOFTWARE.

in

mind the time

of

your marine by

not

strictly

or

destruction

WAR-

EVENT

OUT

in

question

NOTES,

of

the

The WESTERBEKE serial number

number that can assist in detennining the date

of

your WESTERBEKE engine turer's date code is placed number and consists bers. The character indicates the decade (A=1960s, B=1970s, C=1980s, D=1990s

in

the decade: and the second and third numbers repre-

year

of

sent the month

manufacture.

at

of

a character followed by three num-

E=2000s), the first number represents the

is

an

alphanumeric

or

generator. The manufac-

the end

of

the engine serial

of

manufacture

Engines & Generators

3

A

WARNING:

followed,

can

result

Procedures

in

personal

which,

injury

if

not or

properly

loss

of

life.

INTRODUCTION

SERIAL

The engine's model number and serial number are located on a nameplate mounted on the side The engine's serial number (left side) behind the alternator, below the manifold Take the time plate shown below, as this will provide a quick reference when seeking technical information and/or ordering repair parts.

~~~~~~~~~

~1¥fii4il:1B3=t

o 0

• MODEL SPEC

UNDERSTANDING

The diesel engine closely resembles the gasoline engine,

since the mechanism are arranged above a closed crankcase. The crankshaft same general type as a gasoline engine, and the diesel engine has the same type rods and lubricating system.

Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline engine. The most important factors are proper ventilation and proper mamtenance of the fuel, lubricating and cooling systems. Fuel and lubricating filter elements must be replaced ods specified, and frequent checking for contaminants (water, sediment, etc.)

important factor high detergent diesel lubrication oil designed specifically for

diesel engines. The diesel

however, carburetor and ignition systems are replaced component - the fuel injection pump - which performs the function

NUMBER

to

enter this information on the illustration

engine' does differ from the gasoline engine,

in

its

of

both.

LOCATION

of

the engine's manifold.

is

stamped into the engine block

AVO_

MA

USA

THE

DIESEL

is

essentially the same. The cylinders

of

valves, camshaft, pistons, connecting

in

the fuel system is also essential. Another

is

the consistent use

method

of

handling and firing

ENGINE

of

the same brand

of

the name-

SER.NO..

at

the time peri-

of

fuel. The

by

a single

ORDERING

Whenever replacement parts are needed, always provide the engine model number and serial number as they appear on the silver and black nameplate located on the manifold. must provide identify your engine. In addition, include a complete part description and part number for each part needed (see the separately furnished packaged parts because not made to the same specifications

SPARES

Certain spares will WESTERBEKE engine. Your local WESTE.RBEKE dealer

will

a'ssist

the SPARE PARTS page

sories, see WESTERBEKE's

is

the

of

PARTS

us

with this information so

Parts List). Insist upon WESTERBEKE

will fit or generic parts are frequently

AND

ACCESSORIES

be

needed

you

in

preparing

in

we

may properly

as

original equipment.

to

support and maintain your

an

inventory

this manual. For engine acces-

ACCESSORIES brochure.

of

spare parts. See

You

Engines

4

& Generators

ADMIRAL

CONTROL

PANEL

DESCRIPTION

This manually-operated control panel is equipped with a

KEY switch and RPM gauge with an ELAPSED meter which measures the engine's running time in

III 0 hours. The panel also includes a WATER TEMPERATURE gauge which indicates water temperature in degrees Fahrenheit, an engine's oil pressure

OIL PRESSURE gauge which measures the

in

pounds

per

square inch, and a DC control circuit VOLTAGE gauge which measures the tem's voltage. All gauges are illuminated when the key switch is turned on and remain illuminated while the engine

in

operation. The panel also contains two rubber-booted

is pushbuttons, one for PREHEAT and

WATER GRADUATED ILLUMINATED TURNED TEMPERATURE

RPM

GAUGE:

TERS

PER ENGINE RECALIBRATED ACCURACY REAR

REGIS-

REVOLUTIONS

MINUTE

OF

THE

AND

CAN

BE

FOR

FROM

THE

PANEL.

OF

on,?

for START.

TEMPERATURE

IN

DEGREES

WHILE

ON.

THE

ENGINE'S

IS

170·

TIME

in

GAUGE:

FAHRENHEIT

THE

KEY

SWITCH

NORMAL

-190· F (n· -

hours and

sys-

THIS

GAUGE

AND

IS

OPERATING

SS·C).

IS

When the engine is shut down with the key switch turned

off,

the water temperature gauge will continue to register the last

temperature reading indicated power was turned

off

The oil pressure gauge will fall to zero

when the key switch is turned

by

the gauge before electrical

off

The temperature gauge

will once again register the engine's true temperature when

electrical power is restored to the gauge.

A separate alarm buzzer with harness is supplied with every Admiral Panel. The installer

is

responsible for electrically con-

necting the buzzer to the four-pin connection on the engine's

is

electrical harness. The installer the buzzer

in

a location where be audible to the operator should running. The buzzer will sound when the ignition

also responsib,le for installing

it

will

be

dry and where

it

sound while the engine

key

it

is

will

is

turned on and should silence when the engine has started and the engine's oil pressure rises above

OIL

PRESSURE

IN

POUNDS ILLUMINATED ON. PRESSURE

THE

ENGINE'S

15

psi

GAUGE:

PER

SQUARE

WHILE

NORMAL

RANGES

(1.1

kg/cm2).

THIS

GAUGE

INCH

THE

KEY

SWITCH

OPERATING

BETWEEN

40 -85

(PSI)

IS

GRADUATED

AND

IS

TURNED

OIL

pSi.

HOURMETER: REGISTERS TIME, USED THE SCHEDULE.

PREHEAT ALTERNATOR'S

FUEL ENGINE'S OIL BUTTON

START STARTER'S THIS UNLESS AT

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

EXCITER,

SOLENOID

PRESSURE

BUTTON

THE

ON

GLOW

PLUGS.

ALARM

ENERGIZES

BUTTON:

WHEN

SOLENOID

WILL

THE

PREHEAT

SAME

TIME.

BE

FOR

THE

SWITCH.

THE

PRESSED,

WHICH

NOT

BUTTON

PRESSED,

THE

FUEL

INJECTION

IT

BYPASSES

IN

START

BUTTON.

ENERGIZES

CRANKS

OPERATE

ELECTRICALLY

IS

PRESSED

ENERGIZES

LIFT

PUMP,

AND

THE

ENGINE'S

ADDITION,

THE

ENGINE.

AND

THE

THIS

HELD

I/<'

:

~...:

---

,

AUTOMATIC

SUPPLIED REACHES ALARM

OIL LOCATED THE FALL ING SIGNAL.

ALARM

WITH

210· F (99·C),

WHICH

PRESSURE

OFF

ENGINE'S

TO 5 -10

THE

ALARM.

SYSTEM

THE

INSTRUMENT

THIS

WILL

EMIT A CONTINUOUS

ALARM:

AN

THE

OIL

psi

OIL ENGINE'S PRESSURE.

(0.4 -0.7

IN

THIS

EVENT,

OIL

kg/em'),

PANEL.

SWITCH

WILL

PRESSURE

GALLERY.

SHOULD

THE

ALARM

IF

THE

CLOSE

SIGNAL.

ALARM

THIS

THE

ENGINE'S

SWITCH

WILL

SWITCH:

ONLY

THE

IS

BEING

SHOW

COOLANT

THE

IS

MONITORS

OIL

PRESSURE

CLOSE

PROVIDES

TO PANEL

SOUND-

POWER INSTRUMENT CLUSTER.

DC

VOLTMETER: INDICATES BATTERY SHOULb

ENGINE'S

SOUNDING

SWITCH

WILL

EMIT A PULSATING

THE

AMOUNT

CHARGED.

13V

TO

14V.

THE

Engines & Generators

5

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use fuel that meets the requirements 2-D (ASTM), and has a cetane rating

Care

Use only clean diesel fuel! The clearance in your fuel injection pump particles which might pass through the filter can damage these finely finished parts. It and keep it clean. The best fuel can be rendered unsatisfactory by careless handling or improper storage facilities. assure that the fuel going into the tank for your engine's daily use

Purchase a well-known brand

Install and regularly service a good, visual-type fuel filter/water separator between the fuel tank and the engine. The Raycor 445 or larger

ENGINE

80N41120N6 l1OT41170T6

Use the heavy duty engine oils as specified above. Change the engine oil after every

Engine oil viscosity largely affects engine startability, performance, oil consumption, speed seizure, etc. Using lubricants whose viscosity according to the atmospheric temperature

FUEL

or

of

Of

The

Fuel

Supply

is

very critical; invisible dirt

is

important to buy clean fuel,

is

clean and pure, the following practice

of

fuel.

is

a good example

OIL

API

100 hours

ENGINE

I

Grade CF

API

Grade CG-4

an

initial

of

operation thereafter.

ENGINE OIL VISCOSITY CHART

OIL

VISCOSITY GRADE -

I

SAE

lOW

or

CG-4

50

hour break-in period and

of

wearing and occurrence

AMBIENT

SAE

2020W

.1

specification

#45 or better.

of

the components

is

advisable:

of

such a filter.

is

selected

is

important.

TEMPERATURE

SAE

30

of

Class

To

of

_SA.

.I

40.501

OIL

PRESSURE

The engine's oil pressure, during operation, is indicated by the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 25 and 85 psi.

NOTE:

A newly staned, cold engine can have an oil pressure

85

reading up to sure reading as low as depending upon the temperature placed on the engine,

ENGINE

WESTERBEKE recommends a mixture and chemicals that can corrode internal engine surfaces.

The antifreeze performs double duty. It allows the engine to run at proper temperatures by transferring heat away from the engine to the coolant, and lubricates and protects the cooling circuit from rust and corrosion. Look for a good quality antifreeze that contains Supplemental Cooling Additives (SCAs) that keep the antifreeze chemically balanced, crucial to long term protection.

The distilled water and antifreeze should be premixed before being poured into the cooling circuit.

NOTE:

antifreeze that

Antifreeze mixtures will protect against an unexpected freeze and they are beneficial to the engine's cooling system. They retard rust and add to the life

Antifreeze

Freezing

COOLANT

50% distilled water. Distilled water

Look

Concentration

Temperature

psi. A warmed engine can have an oil pres-

25

psi. These readings will vary

of

the engine, the load

and

the RPM's.

of

50% antifreeze

is

free from the

for

the new environmentally-friendly long lasting

is now available.

of

the circulating pump seal.

ANTIFREEZE

PROTECTION

23% 14°F

(-10°C)

(-13°C)

30%

8°F

35%

50%

A

CAUTION:

engine

oil additives to

produce

Do

to

mix.

Each

of

different

properties

not

allow brand

brands

harmful

two

or

more

contains

could

react

to

your

its

in

engine.

brands

own

additives;

the

mixture

COOLANT

A coolant recovery tank kit WESTERBEKE diesel engine. The purpose tank during engine operation, without the loss

of

without introducing air into the cooling system. This provided and must be installed before operating the engine.

NOTE:

located above the level

Engines & Generators

6

RECOVERY

is

to allow for engine coolant expansion and contraction

This tank, with its short run

TANK

is

supplied with each

of

plastic hose, must be

of

the engine's manifold.

\\

,

"

of

this recovery

of

coolant and

kit

is

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting your engine for the first time or after a prolonged layoff, check the following items:

INSPECTION

D Check the engine oil level. Add oil to maintain the level

at the high mark on the dipstick.

D Turn on the fuel supply, then check the fuel supply and

examine the fuel filter/water separator bowl for contaminants.

D Check the transmission fluid leveL

NOTE:

Refer to the previous page

transmission fluid.

for

fuel, oil and

D Check the DC electrical system. Inspect wire connections

and battery cable connections. Make certain the positive

(+) battery cable is connected to the starter solenoid and

(-)

cable

is

the negative stud (this location

D Check the coolant level

and at the manifold.

NOTE:

If

the

engine has not yet been filled with coolant,

refer

to the COOLING SYSTEM section

connected to the engine ground

is

tagged).

in

both the plastic recovery tank

of

this manual.

D Visually examine the engine. Look for loose or missing

parts, disconnected wires, and unattached hoses. Check the threaded connections and engine attachments.

D Make certain there

engine. An ample supply performance.

is

proper ventilation around the

is

necessary for proper engine

D Make sure the mounting installation is secure.

D Ensure the propeller shaft

transmission.

D Open the through-hull and make certain raw water

primed

to

the raw water strainer

is

securely attached to the

is

~

""-..',

DIPSTICK

PUSH

IN

TIGHT

'"

'I

I

\~

~/"

~

~,-~

Engines & Generators

"/',,----

..

'"

.,,,1:'

;,\\1''--

'~I

,,\)1

",'\l'l/

j

?CcC"r~

I

.

i/

MANIFOLD

COOLANT

PRESSURE

CAP

.'"

)

7

STARTING/STOPPING

PROCEDURE

THE

STARTING

These marine diesel engine have start circuitry be depressed for the time specified in the preheat chart. Then, while keeping the button

is

depressed to crank the engine.

Starting

1. Place the transmission control to slightly open.

A

in

neutral. damage vessels

2. Turn the KEY SWITCH to the

3. Depress the lights, gauges, meters and fuel solenoid will be activated.

PREHEAT switch should be depressed

The with the following chart:

SYSTEM

l2V

DC electric starters. The

is

designed so that the PREHEAT button must

PREHEAT button engaged, the START

Procedure

in

neutral and advance the throttle

CAUTION:

to

nearby.

Make

certain Starting your

PREHEAT switch. The voltmeter, panel

in

gear

transmission,

the

transmission

could

result

your

boat,

ON

position (2 o'clock).

in

is

serious

and

in

accordance

TemperatureJPreheat

Atmospheric

41°F(5°C)

23°F(-5°C)

NOTE:

The START button will

HEAT

button

activates the glow plugs in the cylinder head so use the PRE-

HEAT

intem!ittently to avoid overheating the glow plugs.

4. While still depressing the START switch. This will engage the starter solenoid. Upon engine starting, release the START switch and release the

NOTE:

When starting:

A voltage drop will occur

when the preheat button is

depressed.

Temperature

or

higher

to

23°F

(-5°C)

or

lower

not

is

depressed. Depressing the PREHEAT button

PREHEAT switch, depress the

PREHEAT switch.

Preheating

Approx. 5 seconds Approx. Approx.

energize unless the PRE-

12

I

TIme

10

seconds

15

seconds

14

~6

\

",

~

'I,

L....J

\:i

VOLTS

5. Should the engine not start when the START button depressed for 10 to 20 seconds, release both buttons and wait

30 seconds; repeat the procedure above and preheat

longer. Never

A

CAUTION:

the

engine

system

the

pump cooling enter

the

filling

system

manifold from

happening through-hull correcting Engine

damage

warrantable

in

mind.

6. Once the engine starts, check the instruments for proper oil pressure and battery charging voltage.

NOTE:

engine is running.

Starting

Make sure the lubricating oil temperature. Use oil with

30. lOW-30, or 15W-40, or 20W-40.

SAE The battery should be fully charged to minimize voltage drop. Use a sufficient amount

Temperature/Preheat chart elsewhere in this section.

Stopping

To

stop the engine, bring the throttle to an idle position and

place the transmission

a

few

moments to stabilize temperatures. Turn the engine off

using the stop control cable.

NOTE:

Make certain this key switch is in the

(12 o'clock).

discharge. operator of key from the key switch after stopping the engine.

of

preventing the battery from discharging is to remove the

ALTERNATOR

The Admiral Control Panel uses a voltmeter to monitor the performance

run

the

starter

for

more

than

30

Prolonged

starting

wfth

raw

Is

pumping

during

engine's

once

cylinders

the

exhaust

by

closing

shutoff,

the

cause

resulting

issue;

the

Never attempt to engage the starter while the

Under

Cold

cranking

can

result

water.

raw

water

cranking.

by system the

draining of

the

excessive

from

owner/operator

in

the

This

may

through

This

way

fills.

raw

water

the

exhaust

raw

water

Intervals

engine

happen

the

raw

water

of

the

exhaust

Prevent

supply

muffler,

engine

entry

should

exhaust

raw

Conditions

is

appropriate for the prevailing

an

API Specification

of

preheat to aid in starting. See the

of

Procedure

in

neutral. Allow the engine to idle for

OFF

If

the key switch is left

An

engine alarm buzzer is provided to warn the

this condition (key switch ON). The best method

ON,

the battery will

WARNINGS

of

the alternator.

is

seconds.

wfthout

because

water

can

this

and

cranking.

is not a

keep

this

CF

or

CG-4,

position

COOLANT

A coolant temperature switch housing. This switch will activate a continuous alarm coolant's operating temperature reaches approximately 210°F (99°C).

Engines & Generators

8

TEMPERATURE

SWITCH

is

located on the thermostat

if

the

WARNING

LIGHTS,

ALARMS & CIRCUIT

BREAKER

ALTERNATOR

The Admiral Control Panel uses a voltmeter to monitor the performance

COOLANT

A coolant temperature switch housing. This switch will activate a continuous alarm if the coolant's operating temperature reaches approximately

(99°C).

COOLANT SENDOR

WARNINGS

of

the alternator.

TEMPERATURE

SWITCH

is

located on the thermostat

AIR

BLEED

PETCOCK

2IOOF

LOW

OIL

PRESSURE

A

low

oil pressure alarm switch is located off the engine's oil gallery. This switch's sensor monitors the engine's oil pressure. (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.

ENGINE

The DC harness on the engine is protected by mounted manual reset circuit breaker Excessive current draw or electrical overload anywhere instrument panel wiring or engine wiring will cause the breaker to trip. because the opened breaker disconnects the fuel supply. this should occur, check and repair the source After repairing the fault, reset the breaker and restart the engine.

Should the engine's oil pressure fall to 5 -

CIRCUIT

In

ALARM

SWITCH

IO

BREAKER

an

engine-

(20 amps DC).

this event most engines will shut down

of

the problem.

OIL

PRESSURE

(NORMALLY

psi

in

If

the

I

SWITCH

OPEN)

THERMOSTAT HOUSING

OIL

PRESSURE

SEND

OR

FROM BLOCK

ENGINE

Engines & Generators

9

ENGINE

BREAK-IN

PROCEDURE

DESCRIPTION

Although your engine has experienced a minimum hour

of

test operations at the factory to make sure accurate assembly procedures were followed and that the engine operated properly, a break-in time is required. The service life your engine and serviced during its initial

Breaking-in a new engine basically involves seating the piston rings to the cylinder walls. Excessive oil consumption and smoky operation indicate that the cylinder walls are

scored, which is caused by overloading the engine during the break-in period.

Your new engine requires approximately

conditioning operation to break in each moving part in

to maximize the performance and service life Perform this conditioning carefully, keeping lowing:

1. Start the engine according to the

DURE

that all systems (raw water charging) are functioning.

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

is

dependent upon

section. Run the engine at fast idle while checking

130 - 140°F (55 - 60°C) range.

how

the engine is operated

50

hours

of

use.

50

STARTING PROCE-

pump,

oil pressure, battery

of

hours

of

the engine.

in

mind the fol-

one

of

initial

order

3. While using the vessel, run the engine at various engine speeds for the first 25 hours. Avoid prolonged periods idling.

4. Avoid rapid acceleration, especially with a

Use caution not to overload the engine. The presence

5.

grey

or

black exhaust and the inability

speed

reach its full rated

6. During the next 25 hours, the engine may be operated at

varying engine speeds, with short runs at full rated rpm. Avoid prolonged idling during this break-in period.

CHECK

LIST

are signs

of

cold

of

the engine to

an

overload.

of

engine.

of

o Monitor the control panel gauges.

o Check for leaks

of

fuel and engine oil.

o Check for abnormal noise such as knocking, friction.

vibration and blow-back sounds.

o Confirm exhaust smoke:

cold

When the engine is When the engine is When the engine

NOTE:

See the TRANSMISSION section

break-in information on

is

- white smoke.

warm

- almost smokeless.

overloaded - some black smoke and soot.

of

this

manualfor

your

transmission.

a

Engines

10

& Generators

THE

DAILY

ROUTINE

CHECK

Each day before starting your engine, take a few moments to run this check list:

LIST

o Visually inspect the engine for fuel, oil, or water leaks. o Check the oil level. o Check the transmission fluid level. o Check for loose wires at the alternator. o Check the starting batteries (weekly). o Check drive belts for wear and proper tension (weekly). o Log your engine running time. These hours relate to

scheduled maintenance.

o Check fuel supply; always keep fuel tank(s) as full as

possible.

o Look for clean fuel o Check the coolant level

NOTE:

Excessive loss

leak. Check the entire system.

pres'sure tester to pressurize the cooling system to locate

tem

the area the svstem as outlined

secti~n

of

leakage.

of

this manual.

in

the fueVwater separator bowl.

in

the plastic recovery tank.

of

coolant indicates a cooling system

If

necessary, use a cooling sys-

III

cases

of

excessive coolant loss, refill

in

the ENGINE COOLANT CIRCUIT

STARTING

NOTE:

manual

1. Put the transmission

NOTE:

neutral safety switch through which the starter solenoid

energizing circuit passes. This switch transmission energize.

2. Tum the KEY to the ON position (2 o'clock).

3. Depress

4. While pressing PREHEAT, push fires, release START and PREHEAT.

NOTE:

engine. This condition should abate temperature

NOTE:

then repeat the above procedure, and PREHEAT

5. Allow a fortable rpm (approximately rpm, and get underway.

THE

ENGINE

See STARTING/STOPPING PROCEDURE

for

more detailed instructions.

in

neutral, throttle advanced.

Hydraulically operated transmissions have a

is

open when the

is

in gear so the starter solenoid will not

PREHEAT

Some unstable running may occur

is

Should the engine fail to start, wait 30 seconds,

few

(5

seconds).

START.

as

normal operating

reached and loads are applied.

minutes for the engine

to

warm at a com-

1200 rpm), then reduce the

As the engine

in

a cold

in

this

longer.

A

CAUTION:

reduce

the

sion

firmly

in

neutral

high

rpm

engine

from

will

damage

When

rpm

one

allow

shifting

to direction the

the

transmission,

idle,

then

shift

to

another. A slight

propeller

transmission/damper

to

slow.

the

transmis-

Shifting

plate.

always

pauSe

at

Engines & Generators

11

MAINTENANCE

In

order to use this Maintenance Schedule, it will

to

log your engine hours. Use your engine hounneter or

sary record your engine hours

NOTE:

Many

a/the/allowing simple but others are more difficult expert knowledge

0/ a service mechanic.

by

running time.

maintenance procedures are

and

may require the

be

neces-

SCHEDULE

A

WARNING:

while

the equipment correct terminals electrical

tools

Never

engine

is

running.

such

as

goggles

for

each

when

servicing

equipment.

job.

attempt

Wear

and

Disconnect

any

of

to

perform

the

proper

gloves,

the

engine's

and

the

any

service

safety

use

the

battery

DC

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Transmission

Drive

Visual

Fuel

Starting

(and

Engine

Heat

Fuel/Water Exhaust

Engine

Throttle Control

Raw

Separator

Oil

Level

Fluid

Belts

Inspection

Filter

Batteries

House

Batteries)

Oil

and

Exchanger

Separator

System

Hoses

and

Transmission

Cable

Water

Pump

Level

of

Filter

Zinc

,

Engine

Anode

CHECK

EACH

DAY

0 0

0 0 0 0

weekly

0

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000

NOTE:

Keep

engine

surface

oil

will

cool.

inhibit

the

engine's

clean.

ability

to

0 0 0 0 0

0 0 0

0

0 0 0 0

0 0 0

0 0

0 0 0 0

0 0

1250

Dirt

and'

remain

0 0

0

0 0

0

Diesel

No.2

Check

for

if

necessary).

Oil

level

should

dipstick. Check

at

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 Remove

gasket,

cam

and

seals

Lubricate

MAINTENANCE

rating

of

45

cetane

water

and

dirt

in

indicate

between

recovery

the

tank;

if

needed.

should

indicate

proper

tension

if

needed.

fuel,

oil

and

connections.

loose

belt

50

hours

levels

sure

connections

corrosion.

oil & filter

every

100

anode,

end

of

zinc

every

at

50

hours,

leaks.

Check

the

exhaust

buildup

on

necessary.

casting

be

hard & tight.

and

loose

fittings,

with

WD-40

pump and

cover

(the

shaft

when

reassembling.

if

Check

water

tension.

then

every

change

hours.

replace

anode

200

hours.

then

anti-siphon

elbow

inside

Check

integrity.

tighten

cotter

or

cover

for

can

turn,

DESCRIPTION

or

higher.

fuel

(drain/replace

MAX.

and

empty,

check

at

between

equivalent. and

(3/8"

to

1/2"

belt

edges

leaks.

Keep

bolts & nuts

250

50

operating

are

very

at

50

if

needed.

debris.

every

for

carbon

passages;

that

all

Replace

all

hose

pins,

inspect

wear.

Check

but

not

MAX

deflection)

for

Inspect

hours.

tight.

hours,

Clear

250

valve

clean

connections

if

soft

clamps.

etc.

the

wobble).

filter

LOW

manifold.

and

LOW

wear.

wiring

tight.

hours

Clean

then

the

hours.

opera-

and/or

and

or

impeller,

bearings

on

off

heat

are

( continued)

--*

Engines & Generators

12

MAINTENANCE

NOTE:

Use the engine hourmeter gauge to log your engine hours

by

engine hours

running time.

SCHEDULE

or

record your

SCHEDULED

MAINTENANCE

Coolant

System

DC

Alternator

Transmission

Engine Damper

*Fuellnjectors

*Starter

*Preheat

*Engine

Compression

*

Adjust

*Heat

Lubricate with

"Lockeze"

Transmission

Fluid

Feed Turbocharger

Oil

Transmission

Plate

Motor

Circuit

Cylinder

the

Valve

Exchanger

Panel

and

Filter

Pump

Strainer

Cooler

Clearances

Key

Switch

CHECK

EACH

DAY

HOURS

OF

OPERATION

100

250

500

750

50

1000

0

0 0

0

0 0

0

0 0 0

0

0 0 0

0

0 0 0 0 0

0

1250

0

0 0 0

0

0 0 0 0 0

Drain,

flush,

appropriate Check

bracket;

Remove;

tested.

Chattering of

damper

Check spray

condition

Check and

lubricate.

pinion Check

clean

glow

compound Check

compression

(see

ENGINE

Adjust

ADJUSTMENTS).

Remove,

tested. At

first

Initial

fluid

300

hours

fluid

change.

Clean

every

Initial

0

50

and

exhaust tightness. and

axil bearings.

MAINTENANCE

and

refill

antifreeze

DC

charge

from

tighten

electrical

have

professionally

at

idle

and

plate

wear.

and

adjust

injection

(Refer

solenoid

drive. operation

Valve

and

Clean

of

preheat

plugs.

Reinstall

on

threads.

pressure

ADJUSTMENTS).

Clearances,

have

professionally

100

hours,

then

change

at

or

at

winterizing.

250

operating

hour

check,

leaks.

Check

for

play

of

the

rotor

DESCRIPTION

cooling mix.

alternator.

connections.

cleaned

low

rpms

Remove

opening

to

your

motor

for

and

lubricate

solenoid.

with

and

(see

ENGINE

cleaned

each

year

25

hours,

Replace

hours.

inspect

mounting

air

leakage.

shaft.

system

with

Check

and

is

an

indication

and

replace. pressure

service

manual).

corrosion.

the

starter

Remove

anti-seize

timing,

and

at

winterizing.

then

every

the

all

connections

bolts

Inspect

Lubricate

mounting

pressure

and

Remove

motor

and

pressure

filter

at

each

for

the

radial

the

shaft

oil

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

13

mechanic.

COOLING

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine combustion and friction which circulates throughout the engine. This circulating fresh water coolant cools the engine block, its internal moving parts, and the engine oil. The heat is transferred externally from the fresh water coolant to raw water by means exchanger, similar water flows through the tubes fresh water coolant flows around the tubes; engine heat transferred to the fresh water coolant is conducted through the tube walls to the raw water which exhaust system where finally other words, the engine coolant transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent each other. Using only fresh water coolant within the engine

.allows the cooling water passages to stay clean and free from

harmful deposits.

FRESH

NOTE:

ommended antifreeze and water mixture to be used as the

fresh water coolant.

is

cooled by raw water, and the raw water carries the

WATER

Refer to the ENGINE COOLANT section

is

transferred to fresh water coolant

in

function to an automotive radiator. Raw

of

the heat exchanger while

is

then pumped into the

it

is

discharged overboard. In

is

cooled by fresh water coolant, this

COOLING

CIRCUIT

for

by

of

a heat

the rec-

of

SYSTEM

NOTE:

Periodically check the condition

sure cap. Ensure that the upper and lower rubber seals are

good

condition and check that the vacuum valve opens and

closes tightly. Carry a spare cap.

CHANGING

The engine's coolant must be changed according

MAINTENANCE SCHEDULE.

become contaminated, it can lead to overheating problems.

A

critical; a substantial

traced

Drain the engine coolant by loosening the drain plug on the engine block and opening the manifold pressure cap. Flush the system with fresh water, then start the refill process.

COOLANT

CAUTION:

back

Proper

to

cooling

number

system

of

If

the coolant

system

of

engine

corrosion.

the manifold pres-

to

the

is

allowed to

maintenance

fai/ures

can

ill

is

be

is

Fresh water coolant circulating pump, absorbing heat from the engine. The

coolant then passes through the thermostat into the manifold, to the heat exchanger where it engine block via the suction side

When the engine is started cold, external coolant flow prevented flow manifold from overheating). As the engine warms up, the thermostat gradually opens, allowing full flow coolant cooling system.

Coolant

A coolant recovery tank allows for engine coolant expansion and contraction during engine operation, without any significant loss the cooling system. This tank should be located at the engine manifold level and should be easily accessible.

TO TANK

)I-

by

the closed thermostat (although some coolant

is

bypassed around the thermostat to prevent,. the exhaust

to

flow unrestricted to the external portion

Recovery

COOLANT

RECOVERY

pumped through the engine by a

is

cooled, and returned to the

of

the circulating pump.

of

the engine's

of

Tank

of

coolant and without introducing air into

or

~

COOLANT

RETRACTION

is

the

above

A

WARNING:

Wear

protective

Beware

gloves.

DRAIN

of

PLUG

PETCOCK

the

hot

engine

coolant.

COOLANT

EXPANSION

Engines & Generators

14

SOME

ENGINE

TO

BE

MODELS ATTACHED

WITH A PETCOCK A

HOSE

THAT

...........

ARE

EQUIPPED

ALLOWS

'\-

...

,

I

FOR

COOLING

SYSTEM

Refilling

After closing the engine block drain, pour clean, premixed

coolant into the manifold and when the coolant

the manifold, start the engine and run it at slow idle. the air bleed petcocks housing.

Monitor the coolant the from install the pressure cap.

Remove the cap coolant mix to halfway between the cap. Run the engine and observe the coolant expansion flow thermostat housing

After checking for leaks, stop the engine and allow it to cool. Coolant should draw back into the cooling system engine cools down. Add coolant to the recovery tank if

needed. Clean

the

Coolant

is

on

the manifold and the thermostat

in

the manifold and add

manifold

the

into the recovery tank. When the petcock on the

~'

to

the filler neck and when the coolant flowing

petcock

is

free

of

on

the coolant recovery tank and

is

free

up

any spilled coolant. . /

..---'

"\

AIR

BLEED

PETCOCK,

y--..

air bubbles, close the petcock and

LOW and MAX and replace

of

air bubbles, close that petcock.

/

~.,.

Q

.~,

~~~0:r~:1!~

"'\j

~\}~"

_<\11'

as

needed. Fill

visible in

Open

fill

with

as

the

Replacing

Remove the cap screws and disassemble the thermostat housing as shown. When installing the new thermostat and gasket, apply a thin coat pressing it into place. Do

Run the engine and check for normal temperatures and that there are

the

Thermostat

of

sealant on both sides

not over-tighten the cap screws.

no

leaks at the thermostat housing.

of

the gasket before

TEMPERATURE

'.ij,j

//

https://manualmachine.com/-

THERMOSTAT

A thennostat, located near the manifold at the front

engine, controls the coolant temperature as the coolant

continuously flows through the closed cooling circuit. When the engine vents coolant from flowing (some coolant through a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens. The thermostat and can be checked, cleaned, or replaced easily. Carry a spare thermostat and gasket.

is

first started, the closed thermostat pre-

I'

is

by-passed

is

accessible

of

the

THE

GASKET FITS EDGE

IS

AROUND

OF

THE

GROOVED

THE

OUTER

THERMOSTAT

CHANGING

THE

THERMOSTAT

Engines & Generators

15

COOLING

RAW

WATER

The raw water flow is created by a positive displacement

impeller pump. This pump draws water directly from the raw water source (ocean, lake, water strainer. through the raw water pump to the heat exchanger (through the heat exchanger tubes) where it cools the engine circulating fresh water coolant. The raw water is then discharged into the water-injected exhaust elbow, mixing with and cooling the exhaust gasses. This mixture water

is

discharge pressure.

Raw

Water

The raw water non-ferrous housing and a neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate

within the impeller housing, producing the pumping action. On no account should this pump be run dry as water acts lubricant for the impeller. There should always be a spare

impeller and impeller cover gasket (an impeller kit) aboard.

Raw water pump impeller failures occur when lubricant (raw

water)

is are not warrantable, and operators are cautioned to make sure raw water flow is present at start-up.

NOTE:

Should a failure occur with the (seals and bearings). it chase a new

COOLING

The

raw water passes from the strainer

discharged overboard by the engine's exhaust gas

CIRCUIT

or

river) through a hose to the

of

exhaust gas and raw

Pump

pump

is a self-priming, rotary pump with a

not present during engine operation. Such failures

pump

pump's

may be more cost efficient to pur-

and

rebuild the original pump

internal parts

as

a spare.

as

SYSTEM

Changing

Close the raw water intake valve. Remove the pump cover

and, with the aid impeller out Move the blades to conform to the curved cam plate and push the impeller into the pump's housing. When assembling, apply a thin coating gasket.

To

be certain the pump

and check the following:

o Inspect the raw water pump for leaks. o After warm up, monitor the temperature gauge. It should

indicate a normal engine temperature.

o Check aft. There should be a steady flow

the stem tube.

a

A

impeller, cooling exchanger.

Impeller

WESTERBEKE recommends using an impeller puller to remove the impeller, this will prevent damage to the blades and to the edges

the

Raw

of

an

of

the pump. Install the new impeller and gasket.

Open the

CAUTION:

circuit.

they

raw

If

any

must

They

Puller

of

the pump housing.

Water

Pump

impeller puller, carefully pry the

of

lubricant to the impeller and

Impeller

water intake valve.

is

operating properly, run the engine

of

the

vanes

have

broken

be

found

to

onen

can

prevent

be

blockage

found

in

of

water from

the

heat

off

in

the

INSPECTION: EACH

BLAOE REPLACE ARE

WHEN THE KEY. EITHER THE PUMP

GREASE CHAMBER

TO

FEW

THE OF

EASIER.

THE

ANY

CRACKS.

INSTALLING:

IMPELLER

FOLD

THE

DIRECTION

CORRECT

STARTS).

THE

WITH

PROVIDE

SECONDS

GREASE

THE

BLADES

LUBRICATION

IMPELLER

CHECK

AT

BY

IMPELLER

BLADES

IMPROVES

THE

BENDING

TAKE KEYWAY IMPELLER

(THEY

POSITION

AND

PETROLEUM

THE

PUMP

AND

MAKES

BASE

OF

VIGOROUSLY.

IF

THERE

CARE

TO

WITH

WHEN

THE

ALIGN

THE

SHAFT

BLADES

IN

WILL

TURN

THE

PUMP

JELLY

FOR

THE

HAS

TO

RUN

SEAL INSTALLATION

IN

DRY.

THE

O-RING ONLY REPLACED SIGNS

NEEDS

IF

OF

WEAR.

GASKET

TO

BE

IT

SHOWS

WATER

LEAKING INDICATE FAILED

AND

IMMEDIATE

~~~ft-*""---HOUSING

RAW

.

WATER

..

PUMP

THE

PUMP

THE

SERVICE.

HERE

SEAL

PUMP

WOULD

HAS

NEEDS

Engines & Generators

16

COOLING

HEAT

EXCHANGER

The heat exchanger large number through the small copper tubes and the fresh water coolant from

the engine

raw water removes heat from the fresh water coolant.

Heat

Exchanger

After approximately 1000 hours and pressure test the engine's heat exchanger. (A local automotive radiator shop should exchanger.)

NOTE:

Operating that a heat exchanger cleaning be perfonned more often than every

1000 hours.

Zinc

Anode

A zinc anode, or pencil, circuit within the heat exchanger. The purpose zinc anodes place effects The condition and the anode cleaned or replaced as required. Spare anodes should be carried on board.

NOTE:

installation and vessel location; not that

is

in

the raw water cooling circuit, thereby reducing the

of

electrolysis on other components

Electrolysis action is the result

is

a copper cylinder which encloses a

of

small copper tubes. Raw water

is

circulated around the copper tubes. The

is

pumped

Service

of

operation, remove, clean

be

able to clean and test the heat

in

silty and/or tropical waters may require

is

located

to sacrifice them to electrolysis action taking

of

the zinc anode should be checked monthly

in

the raw water cooling

of

having

of

the system.

of

each particular

of

the engine.

SYSTEM

ZINC

ANODES

NEW

If the zinc anodes need replacement, hold the hex boss into which the zinc anode

ening the anode with another wrench. This prevents the hex

boss from possibly tearing off the exchanger shell. After removing the zinc, note the condition poor condition, there are probably a lot the exchanger. Remove the end

clean the inside exchanger end gasket

aged when removing the end cover. Replace the gasket (refer

to

your engine model's heat exchanger end gasket part num-

ber),

O-ring and cover, and install a new zinc anode.

NOTE:

The threads

do

not require sealant. Sealant should not be used as it may insulate the zinc from the metal ing preventing electrolysis action on the zinc.

of

REPLACE

is

threaded with a wrench while loos-

of

the heat exchanger and

all zinc debris. Always have a spare heat

in

case the present one becomes dam-

of

the zinc anodes are pipe threads and

of

the heat exchanger hou;-

CLEAN & REUSE

it.

If

the zinc

of

zinc flakes within

is

in

CLEAN

OUT

BOTH

ENDS

ZINC

ANODE

ALSO

SERVES

FOR

THE

RAW

AS A DRAIN

WATER

SYSTEM

HEAT

EXCHANGER

TO

REMOVE

HEAT

EXCHANGER

17

CLEAN

GASKET

OUT

ACCUMULATED

DEBRIS

COOLING

Raw

Water

NOTE:

the strainer will always be self-priming.

A clean raw water intake strainer is a vital component engine's cooling system. Include a visual inspection strainer when making your periodic engine check. The water in the glass should be clear.

Perform the following maintenance after every operation:

1.

Close the raw water seacock.

2. Remove and clean the strainer filter.

3. Clean the glass.

4. Replace the washer if necessary.

5. Reassemble and install the strainer.

6.

Open the seacock.

7. Run the engine and check for leaks.

Intake

Always install the strainer

Strainer

at

or

below the waterline so

100 hours

of

this

the

of

SYSTEM

NOTE:

Also follow the above procedure after having run hard

aground.

If

the engine temperature gauge ever shows a higher than normal reading, the cause may be that silt, leaves or grass may have been caught up in the strainer, slowing the raw water through the cooling system.

WASHER

STRAINER FILTER

flow

of

AIR

INTAKE

DESCRIPTION

A marine diesel engine will typically consume 6,000 cubic feet

be

room

unrestricted. The air intake filter/cleaner should be inspected

every

100

of

air per hour. Not only must the engine

well ventilated, the air flow into the engine must be

operating hours. Clean/replace when needed.

AIR

INTAKE

FILTER

as

much

as

TYPICAL

FILTER

RAW

WATER

tOwner

........

--CONNECTS

INTAKE

Installed]

ARM

COVER

STRAINER

TO

ROCKER

Engines & Generators

18

FUEL

SYSTEM

DIESEL

Use use

FUEL

A primary fuel filter installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine.

Most installers include a type the installation package as they are aware that contaminants in the fuel can cause.

A typical fuel filter/water separator is iIIustrated below. This is separator type filter is not installed between the fuel supply tank and engine-mounted fuel system, any water in the fuel will affect the fuel pump, engine filter, and injection equipment. The owner/operator is responsible for making certain the fuel reaching the engine's injection equipment free and maintaining a proper filtration/separation system.

FUEL WATER

[Owner

FUEL

No.2 diesel

kerosene or home heating

WATER

the Raycor Model 445. Keep in mind that

of

impurities. This process is accomplished by installing

FILTER!

SEPARATOR

Installed]

fuel

with a cetane rating of 45 or

fuel.

SEPARATOR

of

the water separating type must be

of

filter/water separator with

higher.

of

the problems

if

a water

Do

not

is

FUEL

FILTERS

The

fuel injection pump and the fuel injectors are precisely

manufactured and they must receive clean diesel fuel, free

of

valve

Take

fire

near

clean fuel, the

at

the

care

in

catching

any

smoking,

the

fuel

ventilation

from water and dirt. To ensure this flow must pass through at least two fuel filters. a fuel/water separator and the engine's spin-on fuel filter. Visually inspect, clean. and change these filters according to the maintenance schedule in this manual.

A

WARNING:

when

servicing

any

fuel

that

open

flames

system

when

servicing

Shut

the

fuel

may

spill.

or

other

sources

servicing.

the

fuel

off

the

system.

DO

NOT

Ensure system.

fuel

allow

of

proper

tank

exists

LIGHTLY WITH

fuel

CLEAN

WIPE

FUEL

INJECTION

The

fuel

injection pump

diesel

engine. requiring the utmost care injection pump owner-operator

requires servicing, remove injection pump service facility. Do not attempt and

repair

it.

The

only

adjustment the servicing mechanic should make to

fuel

injection pump

FUEL

LIFT

The

fuel

lift

pump

PUMP

is a very

has

been thoroughly bench-tested

is

cautioned not

is

the adjustment for engine idle speed.

important component of the

in

to

attempt

it

and take

it

to

PUMP

is

an

integral part of

the

handling. The

to

an

fuel

and

the

service

it.

If

authorized

to

disassemble

injection pump.

it

fuel

the

TO

LlFTPUMP

AND

INCOMING

FUEL

TO

INJECTION

PUMP

Changing

1.

Shut

2. Loosen the fuel filter, turning counterclockwise with a filter wrench. Place the used filter in a container for proper disposal.

3.

Using a rag, wipe clean the sealing face on the housing bracket so the new filter can

4. Lightly oil the sealing O-ring on the new filter. To rein-

stall, turn the filter assembly counterclockwise carefully until the O-ring contacts the sealing surface bracket. Turn 2/3 further with the filter wrench.

NOTE:

during disassembly.

the

Fuel

Filter

the fuel supply off.

be

The cartridge contains fuel.

seated properly.

of

Take

care not to spill it

the housing

Engines & Generators

19

FUEL

FEED

PUMP

An additional fuel screen is located in the feed pump. This screen (strainer) banjo bolt at the bottom. This screen should be cleaned every 250 operating hours. Use compressed air and/or clean with

kerosene.

STRAINER

is

removed for cleaning by releasing the

TO

FUEL

FILTER

INJECTION BLEED

PUMP

SCREW

SYSTEM

BLEEDING

1. Loosen the bleeding screw on the fuel injection pump.

2. Tum the feed pump knob counterclockwise until the pump knob

3. Depressing the mixed fuel from the loosened bleeding screws.

4. Repeat the pumping action until no bubbles are visible the flowing fuel.

5. Tighten the bleed screw and the feed pump knob.

FUEL

If

fungus or bacteria an authorized dealer correct these problems. Then use a diesel fuel biocide instructions

(PRIMING)

is

forced up by the spring.

THE

FUEL

SYSTEM

pump

knob will cause it to drain out the air

ADDITIVES

is

causing

to

sterilize the fuel (follow the manufacturer's

).

fuel

problems, you should have

in

FEED

PUMP

FUEL

FEED

PUMP

1.4---

After changing the fuel filter strainer, WESTERBEKE dure for ensuring there is no air trapped in the fuel system.

BANJO BOLT

and

cleaning the fuel feed pump

recommends

the following proce-

SPARE

While the likelihood slim, the possibility does exist. Therefore, banjo washers, injector seat washers board at WESTERBEKE dealer or distributor.

a banjo washer that cannot be corrected by a simple tightening of the fitting, replace the sealing washer with a replacement found the hardware kit for your model.

PARTS

of

having to service the system

we

and a fuel

all

times. Purchase needed spare parts from your local

If

a leak should develop

at

recommend that

filter

be

sea is

carried on

at

in

Engines & Generators

20

ENGINE

LUBRICATING

DESCRIPTION

The lubricating system

oil pump. The engine oil oil pump, which drives the oil, under pressure, through the

filter, oil cooler and various lubricating points

oil engine. The oil then returns to the oil sump to repeat the continuous cycle. When the oil pressure exceeds the specified pressure, the oil pushes open the relief valve oil pump and returns to the oil sump, keeping the oil pressure within its specified range.

Oil

Pressure

The engine's oil pressure, during operation,

by the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 25 and 85

psi.

is

a pressure feeding system using

is

drawn from the oil sump by the

in

is

indicated

the .

in

an

the

OIL

NOTE:

Generic filters are not recommended. as the mater-

ial standards

parts might

Immediately after an oil filter change engine to make sure the oil pressure is normal there are no oil leaks around the new oilfilter.

3.

Filling the Oil Sump. Add new oil through the oil filler

cap on the top engine for a few moments while checking the oil pressure. Make sure there oil filter or from the oil drain system, and stop the engine. Then check the quantity Fill to, but not over the high mark on the dipstick, should the engine require additional oil.

or

diameters

be

entirely different from genuine parts.

of

the engine. After refilling, run the

of

important items on generic

and

oil fill.

is

no

leakage around the new

of

oil with the lube oil dipstick.

and

run

the

that

ENGINE

1.

2.

OIL

CHANGE

Draining the Oil Sump. Discharge the used oil through

of

the sump drain hose (attached to the front

while the engine is wann. Drain the used oil completely,

in

replace the hose

=urely.

SUMP DRAIN

HOSE-

Always observe the used oil as it yellow/gray emulsion indicates the presence the oil. Although this condition prompt attention to prevent serious damage. Call a qualified mechanic should water be present

Raw water present the exhaust system attached to the engine and/or a siphoning circuit into the exhaust, filling the engine. This problem often caused by the absence poor location

of

Draining the Oil

flows from the drain (into an appropriate container). After draining, remove the filter and wipe off any excess oil.

Tighten the

When installing the new oil filter element, wipe the filter's O-ring gasket's sealing surface free apply a thin coat on the

new

oil filter. Screw the filter onto the threaded oil filter nipple on the oil filter bracket, and then tighten the filter firmly by hand.

its bracket, and replace the end cap

.

1\

~

__

~

in

the oil can be the result

raw water through the raw water cooling

or

lack

of

maintenance.

Filter.

Back off the drain plug until oil

drain

plug.

of

clean engine oil to the rubber O-ring

'~~~

is

removed. A

is

rare, it does require

of

an

anti-siphon valve, its

the engine)

of

water in

in

the oil.

of

oil and

6"0.0.

a fault

FOR

EXTENSION

1/4"

NPT

in

is

SPIN

ON

OIL

FILTER

TURN

HAND

O-RING.

THEN

2/3

OF A TURN.

O-RING

APPLY

CLEAN

ENGINE

OIL

WHEN

INSTALLING

CUSTOMER

THIS

WIRE

USED

TO GAUGE OEVICE

THE THE WIRE

BUNDLED

WIRING

CHANGING

ATTACH

OR

ALARM

TO

MONITOR CONDITION OIL

FILTER.

IS

CURRENTLY

INTO

HARNESS.

THE

TIGHT

AGAINST

TIGHTEN

OPTION

CAN

BE

A

OF THE

THE

ENGINE

OIL

Engines

21

& Generators

REMOTE

OIL

INSTALLATION

This popular accessory ter from the engine to a more convenient location such as an engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE in this manualfor

instructiollS on removing the oil filter.

A

CAUTION:

correctly.

by-pass

from failure.

immediately

If

the

valve

reaching

If

there

and

In

the

Is

It

011

the

is

used to relocate the engine's oil fil-

Is

Ifltal

to

Install

the

oill/nes

flows

In

filter

engine

no

011

check

themvelSB assembly causing

pmssuTB

the

hose

dlmctlon,

will

prevent

an

Intemal

reading,

shutdown

connections.

the

011

engine

NOTE

THE

ON

THE

ADAPTER REMOVED WILL

BE

RECONNECTED

"IN" FOR

FILTER

AND

"OUT"

WHEN

INSTALLATION

(OPTIONAL)

To

install, simply remove the engine oil filter and thread on WESTERBEKE's remote oil filter kit as shown. Always install this kit with the oil filter facing down as illustrated.

Contact your WESTERBEKE dealer for more information.

NOTE:

Westerbeke is not responsible

incorrect installation

MARKINGS

THE

HOSES

ARE

SO

THEY

CORRECTLY.

of

the Remote Oil

for

engine failure due to

Filter.

FASTEN

SECURelY

(SCREWS

ARE

OWNER

TO A BULKHEAD

SUPPLIED)

APPLY A COAT INSTALLING TIGHTEN

AN

CONTACTS

OF

THIS

KIT.

ADDITIONAL

THE

BASE.

CLEAN

THREAD

3/4

TURN

OIL THE

TO

THE

KIT

ON,

AFTER

O-RING

THEN

THE

O-RING

WHEN

HAND

Engines & Generators

22

APPLY A THIN TER

GASKET

FILTER

CONTACTS

ADDITIONAL

I

COAT

WHEN 3/4

TURN.

THE

OF

CLEAN

BASE,

OIL

TIGHTEN

INSTALLING.

TO

THE

AFTER

THE

IT

AN

FIL-

WATER

As

an

accessory, WESTERBEKE that directs the engines hot water (coolant) flow to heat the fresh water

ENGINE FRONT

HOSES CONNECT THE

TANK

CONNECTION)

TO

HOT

WATER

(EITHER

in

the ships hot water tank.

CUT MOLDED

PROVIDE CONNECTIONS ARE

THE

HEATER

wiJI

provide a connector

ROCKER COVER

THE

DISCARDED

HOSE

TO

THE

TWO

NEEDED CONNECTOR ENGINE

THAT

TO

ATTACH

TO

CONNECTION

HOSE

(OPTIONAL)

The water heater shouKl be mounted either

in

a high or low position that the connecting hoses from the heater to the engine can run

in

a reasonably direct line without any loops which

might trap air. Hoses should rise continuously from their low point at the

heater to the engine so that air will rise naturally from the heater to the engine. then

an

air bleed petcock must be installed at the higher

fitting on the heater for bleeding air while filling the system.

NOTE:

If

any portion

engine's closed cooling system pressure cap, then a pressurized (aluminum) remote expansion tank (Kit #024177) be installed in the circuit to become the highest point.

remote expansion tank into the heater circuit, choosing the

of

higher

heater; the other back to the engine's return. Install the remote expansion tank in a convenient location so the fresh water coolant level can easily be checked. The remote expansion tank will now serve as a check

the two connections

and

plumb a single line up

plastic coolant recovery

expansion

tank

If

trapped air is able to rise

of

the heating circuit rises above the

tank

kit

is

installed, since this

same function.

REMOTE TANK

EXPANSION

in

a convenient location

in

relation to the engine, so

to

for

the return.

to

and

system fill point. The

is

not

used

Tee

the tank's location and

when the remote

tank

serves the

the heater,

must

Tee

at the

the

WATER HEATER

Engines & Generators

23

DC

ELECTRICAL

SYSTEM

ALTERNATOR

The charging system consists with a voltage regulator, an engine mounted DC circuit breaker and a battery with connecting cables. Because electronic voltage regulator internally or

#14

GRAy==#=w

#14

PINK

#14

~~~~~~~fiC--

BLUE=

of

the use of integrated circuits (lC's), the

on

the back

of a DC

DC

is

very compact and

of

the alternator.

__

......

belt driven alternator

wiring harness, a

is

(9)~~=#14

iB@lillili====

SEE

ENGINE GROUND

ALTERNATOR

A

WARNING:

hot.

00

not

touch

Use this troubleshooting section to determine if a problem exists with the charging circuit determined that the alternator or voltage regulator have a qualified technician check it.

The alternator charging circuit charges the starting battery

and the service battery. An isolator with a diode, a solenoid or a battery selector switch to

isolate the batteries so the starting battery along with the service battery. starting battery but not the service battery, the problem the service battery's charging circuit and not with the alternator.

Testing

the

,':1

TROUBLESHOOTING

A

failed

alternator

until

the

alternator

or

with the alternator.

is

usually mounted

If

the alternator

Alternator

FOR TO

can

has

WIRING

WIRE

OPTIONAL

become

cooled

in

is

not discharged

is

charging the

mounted

BROWN

#10

REO

DIAGRAM

CONNECTIONS

ALTERNATORS.

very down.

If

it

is

faulty,

the circuit

is

in

1. Start the engine.

2. After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a multimeter set on

a.

If

the voltage is increasing toward 14 volts, the alternator is working; omit Steps 3 through 8 and go directly to

"Checking the Service Battery" on the next page.

h.If

the voltage remains around exists with either the alternator or the charging circuit; continue with Steps 3 through

DC

volts.

12

volts, a problem

8.

CIDJ

MULTIMETER

o

COM

TESTING

BATTERY

(ENGINE

3. Turn off the engine. Inspect all wiring and connections.

4.

S.

Turn

6. Check the battery voltage.

THE

STARTING

IALTERNATOR

RUNNING)

-=

GROUND

Ensure that the battery terminals and the engine ground connections are tight and clean.

A

CAUTION:

charging switch

when

If

a battery selector switch is in the charging circuit,

ensure that it is on the correct setting.

on

the ignition switch, but do not start the engine.

tion, the reading should be

circuit,

the

To

avoid

never

engine

damage

shut

off

is

running!

If

the battery

12 to

the

13

to

the

engine

volts.

is

battery

in good condi-

A

CAUTION:

that

everyone

sheaves

A

DC applications. iso/ate before made

and

WARNING:

and

AC DC

performing

without a proper

Before

is

clear

belts

circuits

Always

and

AC

starting

of

moving

during

test

procedures.

When

are

testing

often

with a multimeter:

mixed

disconnect a shore

converters,

DC

testing.

and No

know/edge

the

parts!

together

shut

AC

of

engine

Keep

down

.tests

AC

make

away

in

marine

power

cord,

the

should

circuits.

certain

from

engine

be

TESTING ALTERNATOR (IGNITION

Engines & Generators

24

THE

VOLTAGE

ON -ENGINE

OFF)

Cl2ID

~W---MULTIMETER

-=

GROUND

DC

ELECTRICAL

SYSTEM

7. Now check the voltage between the alternator output terIf

minal (B+) and ground. the alternator will tor

is

in the circuit the alternator voltage will be zero.

neither

of between the alternator and the battery. Check all the connections - look for an opening

TESTING

BATTERY

(ENGINE

8. Start the engine again. Check the voltage between the alternator output and ground.

The voltage reading for a properly operating alternator should be between 13.5 and 14.5 volts. is

over- or under-charging, have it repaired at a reliable

service facility.

NOTE:

Before removing the alternator voltmeter to ensure that at

the EXC terminal

tery voltage

If

12

volts is not present

wiring

and

be the same as the battery, or

the above

THE

STARTING

IALTERNATOR

RUNNING)

at

the B output terminal.

look

for

the circuit

is

true, a problem exists in the circuit

12 volts

if

the previous test showed only bat-

at

the

breaks

and

is

good, the voltage at

in

the charging circuit.

M

ULTIMETER

WITCH

~~a+"

I

If

your alternator

for

repair;

DC

excitation is present

EXC

terminal, trace the

poor

connections.

if

an isola-

CI2ID

0

COM

I'

"\..

use a

If

ENGIN GROUND

Checking

Check the voltage have a voltage between running. charging circuit. Troubleshoot the service battery charging circuit by checking the wiring and connections, the solenoid, isolator, battery switch, and the battery itself.

E

A

do

performing

the

Service

If

not, there

MumMETER

GROUND

i

COM

CAUTI,ON:

not

use a high

tests

Battery

of

the service battery. This battery should

13

and 14 volts when the engine

is

a problem in the service battery

SERVICE

TESTING BATTERY

To

avoid

voltage

on

the

damaging

tester

alternator

the

alternator

(i.e. a megger)

charging

BATTERY

THE

SERVICE

(ENGINE

when

circuit.

is

RUNNING)

diodes,

12

VOLT

DC

CONTROL

The engine has a 12 volt DC electrical control circuit that

shown on the wiring diagrams that follow. Refer to these

diagrams when troubleshooting or when servicing the

electrical system.

A

CAUTION:

circuit,

the however, engine's

never

engine

To

shut

is

running.

to

avoid

electrical circuit.

CIRCUIT

avoid

damage

off

the

engine

Shut

electrical

off

the

shorts

to

the

battery

engine

when

battery

switch

battery

working

DC

charging

while

SWitch, on

BAnERY

The minimum recommended capacity the engine's Cranking Amps (CCA).

12

volt DC control circuit

of

the battery used

is

600 - 900 Cold

Battery

is

Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine's starting batteries and house batteries.

o Monitor your voltmeter for proper charging during

engine operation.

o Check the electrolyte level and specific gravity with a

hydrometer.

o Use only distilled water to bring electrolytes to a proper

the

in

Engines & Generators

level.

o Make certain that battery cable connections are clean and

tight to the battery posts (and to your engine).

o Keep your batteries clean and free

A

WARNING:

cause protective

25

Care

severe

gear.

Sulfuric

bums

on

acid

skin

in

and

of

corrosion.

lead

batteries

damage

can

clothing.

Wear

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid. When PREHEAT should

"click" on and the glow plug should begin to get hot.

is

pressed at the control panel this solenoid

INSPECTION

To

inspect the plug, remove the electrical terminal connections, then unscrew or unclamp each plug from the cylinder head. Thoroughly clean each plug's tip and threads with a

soft brush and cleaning solution to remove all the carbon and

oil

deposits. While cleaning, examine the tip for wear and burn erosion;

if

it has eroded too much, replace the plug.

TESTING

An accurate way

Touch one prod to the glow plug's wire connection, and the

other

to

the body of the glow plug, plug will have a used with the plug an ammeter

A

WARNING:

to

the

touch.

testing

the

to

test glow plugs is with an ohmmeter.

as

shown. A good glow

0.4 - 0.6 ohm resistance. This method can be in

or out

of

the engine.

to

test the power drain (5 - 6 amps per plug).

These

glow

plugs

Be

careful

not

to

burn

will

your

You

can also use

become

fingers

very

plugs.

hot

when

~

Re-install the plugs

plugs should get very hot (at the terminal end) within 7 seconds. circuit. When reinstalling the glow plugs, use anti-seize pound

A

Glow

If

the plugs don't heat

on

the threads.

WARNING:

than

30

seconds.

Plug

Tightening

~=:::::;IC;;;;==;;;:;):="""",!~

in

the engine and test them again. The

up

quickly, check for a short

Do

not

keep a glow

Torque

19.5

TESTING A GLOW WITH

AN

OHMMETER

KEYIPREHEAT-QPi

H-Ib

PLUG

(2.7

plug

m-kg)

on

for

more

TERMINAL END

TIP

to

15

com-

GLOW

FROM

PREHEAT

TERMINAL

PLUGS

/;

TESTING A GLOW USING A TEST

LIGHT

PLUG

+

Engines & Generators

26

WIRING

MARINE

SCHEMATIC

ENGINES

#44781

+ ~ • .-______________

IZV ( 24V

20A

C.B C.B

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e:

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c

~

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u

'"

....

.;

~8~AT~T~E~RT~I~2~·2~.~V~O~C~

START

SOl.

________________

STARTER

•

OPTIONAL

ALTERNATORS

ADMIRAL PANEL

KEY

SW.

PREHEAT

SWITCH

TACHOMETER

$

VOLTMETER

PRESlOLllE 12

AMP

PRESlOLllE\LEECE-NEVILLE

DISCONNECT JUMPER

USE

WITH

TWO

BATTERIES.

90

fOR

ALl

AMP

ALl

LESTEK

Engines & Generators

27

135

160.

190

AMP.

ALT.

~l"

!-ZUlli

WIRING

MARINE

ENGINES

DIAGRAM

#44781

ALTERNATOR.

21Y

12A

I----~~~~~t-w_----_rt_------t_--J_--~

"'~"

,~

I I

+~

~-===-

BATTERY

12-21

VDC

(USED

NEUTRAL

rTY

a

WI

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NOTES:

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ADMIRAL PANEL

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REO

Engines & Generators

28

ENGINE

TROUBLESHOOTING

The following troubleshooting table describes certain problems relating to engine service, the probable causes

of

these prob-

lems, and the recommendations to overcome these problems.

No

panel

indications;

or

fuel

pump

is

on

and

PREHEAT

START

button

engagement.

Engine

cranks,

start.

Engine

can't

Battery

runs

Battery

not

charging

Engine

slows

Problem

fuel

is

not

working

button

is

depressed,

but

does

be

stopped.

down.

and·

stops.

solenoid

(key

is

depressed).

no

starter

not

switch

1.

Battery 20-amp

2.

10-amp

3. preheat

4.

Loose

Preheat

5.

Connection

1.

2.

Gear

Faulty

3.

4.

Faulty

5.

Loose Low

6.

Faulty

1.

Preheat

2.

Low

3.

1.

Disconnect

off Oil

1.

2.

High

Low

3. Poor

4.

DC

5.

(tachometer Alternator

1.

Fuel

20

2.

Exhaust

3.

4.

Water

Air

5.

Probable

switch

circuit

breaker

solenoid

battery

solenoid

to

shift

not

switch. solenoid.

battery

battery.

fueling

solenoid

battery

fuel

the

fuel

pressure

resistance

battery

alternator

drive.

starvation.

Amp

circuit

system

in

fuel.

intake

obstruction.

Cause

not

on.

breaker

tripped.

tripped

connections.

not

operating.

solenoid

faulty.

in

neutral.

connections.

system.

faulty.

power.

shut-off

switch.

leak

to

ground.

leak.

connections.

not

charging

not

operating).

breaker

is

restricted.

NOTE:

The engine's electrical system is protected by a ampere manual reset circuit breaker located on a bracket the back

of

the engine. The preheat solenoid is mounted on

the same bracket.

VerificationJRemedy

Check

switch

and/or

battery

connections.

trips

again.

for

shorts

at

and

after

for

it

to

starter

Check

battery

terminal

for

in

neutral

(see

are

present

state.

are

open.

system.

Bleed

Replace

filters

house

and

shut-off

lever.

panel

lights

the

oil

pressure

sensitive

engine.)

Remove

temperature

at

battery

check

belt

alternator

Check

Exc.

terminal.

valves,

overly

sensitive

button

to

collapsed

tank(s);

cartridge.

output

draw

the fuel amperage

fuel

to

the

cool

then

solenoid

cable

voltage.

NEUTRAL

at

the

air and

start

batteries.

Pull

are

(0 -.25

rise

for

tension,

should

fuel

lift during

reset.

hose,

change

on

cable.

tripping.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

1. 1a.

1

2.

3. 3a.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

b.

Reset circuit

Check preheat

Check engine

Check Check

Gear

HURTH

Check Check Check Check Check

Check Fuel

fuel Check

Switch Replace

Check

Observe is

Check lines. after

Check

Check corrosion

Check

DC

Check for volts

Check Check

Ensure cause

Check exhaust

Pump bleed

Check

breaker;

if

and the

(+)

ground

solenoid

connection.

shift

switch that battery battery that

for

filters

system.

solenoid.

connection

not

running.

wiring.

(Do

short

all cable

connections,

ELECTRICAL

drive

loose

are

tripping.

fuel

breaker

check

circuit

voltage

solenoid -wait

connection

stud.

"S"

must

be

TRANSMISSIONS).

with

12

volts connections. charge

fuel

valves

air

in

fuel

clogged.

to

combine

batteries.

if

gauges

Test

Insert

not

start

is

located.

wires

for

connections

SYSTEM/ALTERNATOR.

belt

tension;

connections.

present

fuel

supply,

for

high

DC

breaker

is Push

for

blockage,

elbow.

water

from

system.

air

intake

filter

both

ohmmeter.

at

and

at

not

check

preheat

ground.

breaker

on

res~t.

and

(-)

connections.

SWITCH

solenoid

connection.

from

fuel

bleed

air

lever

back

activated

switch.

amp)

meter

connections

to

locate

the

loose

connections,

test

alternator.

turn

with

voltmeter.

pump.

operation.

to

heat

which

carbon

buildup

filters

and

20

solenoid

the

connection

under

system.

from

to

close

when

engine

in

battery

and

replace

fault.

See

freely.

Check

Ensure

would

at

to

12

(continued)

Engines & Generators

29

ENGINE

TROUBLESHOOTING

Engine

Exhaust

Problem

overheats.

alarm

sound

alarm

sounds

smoke

problems

pulsates.

continuously.

1.

2.

1.

2.

1.

2.

1.

2.

3.

Probable

Raw

water

Coolant

Loss

of

Oil

pressure Engine High

temperature

too

Iowa

Blue

smoke.

White

Black

smoke.

not

circulating.

not

circulating.

oil.

switch.

coolant.

temperature.

smoke.

Cause

switch

opens

at

Verification/Remedy

1.

Raw

water

pump

failure.

Check

impeller -replace.

2.

Obstruction

2a.

Thermostat -remove

Replace

2b.

Loss lor

2c.

Broken

2d.

Air bleed

Check

1. oil

Replace

2.

1.

Check

.

2.

Check check

Incorrect

1. 1a.

Crankcase through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel

insufficient

exhaust

3b.

Improperly

3c.

Lack ventilation.

3d.

Overload.

at

thermostat.

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add

dipstick,

drain

hose

oil

pressure engine for

satisfactory

with

ohmmeter,

grade

is

overfilled

the

exhaust).

is

running

injector

grade

burn

incomplete

air

system;

timed

of

air -check

raw

water

intake

or

raw

and

test

in

hot

hoses,

hose

belts -tighten/replace.

run

engine

and

coolant

as

look

for

oil

connection.

switch.

coolant

level.

operation

replace

of

engine

with

cold.

or

incorrect

of

fuel.

due

for

proper

check

air

injectors

air

intake

open

needed.

leaks

at

oil

with

if

faulty.

oil.

engine

oil

injector

timing.

to

high

back-pressure

combustion

intake).

or

valves,

and

air

water

water.

clamps,

the

filter

switch

(oil

is

(check

or

poor

filter.

drain

plug,

pressure

cap

and

at

bypassed,

blowing

out

in

exhaust

for

restrictions

compression.

Check

for

proper

etc.

to

or

in

TROUBLESHOOTING

If

the

gauge reading

by

the

gauge when the instrument panel

step

is

to

check for

and

the

Negative

Assuming that there is

is

other than what is nonnally indicated

12

volts DC between the ignition (B+)

(B-)

tenninals

12

of

the gauge.

volts as required, leave the

COOLANT

is

energized, the first

TEMPERATURE

instrument panel energized and perfonn the following steps:

1.

Disconnect the sender wire at the gauge and see if the

is

gauge reads zero, which

the nonnal reading for this

situation.

2.

Remove the wire attached to the sender tenninal at the sender and connect it full

scale, which

to

ground. See if the gauge reads

is

the nonnal reading for this situation.

Engines & Generators

AND

OIL

PRESSURE

If

both

of

the above gauge tests are positive, the gauge undoubtedly conductor from the sender

If

either

OK

and the problem lies either with the

of

the above gauge tests are negative, the gauge

GAUGES

to

the gauge or with the sender.

probably defective and should be replaced.

Assuming the gauge

to

sender

the sender tenninal at the gauge for continuity.

Check that the engine block

is

OK, check the conductor from the

is

connected

to

the ground. Some starters have isolated ground tenninals and if the battery

is

connected

to

the starter (both plus and minus tenninals), the ground side will not necessarily be connected to the block.

30

is

TACHOMETER

TACHOMETER/HOUR

The tachometerlhour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. other the tachometer. The hour volts alternator charging voltage supplied to the (+) terminal on

the back

The tachometer circuit operates on AC voltage 6-8 volts, fed from one

tachometer input terminal while the engine is running, and the alternator producing battery charging voltage 13.0-14.8 volts DC.

The following are procedures to follow when troubleshooting a fault in either meter.

Hour

Check for the proper DC voltage between (+) and (-)

terminals.

1.

Voltage present - meter is defective - repair or replace.

2.

Voltage not present - trace (+)

nections for fault. (Jump terminal to verify the operation.)

Tachometer

Check for the proper AC voltage between tachometer input terminal and (-) terminal with the engine running.

1.

Voltage present - attempt adjusting meter through calibration access hole. No results, repair or replace meter.

2.

AC output voltage.

3. Check for ground.

4. Check electrical connections from tachometer input terminal to alternator connection.

of

the instrument.

of

the diodes

of

meter

Inoperative

voltage not present - check for proper alternator DC

AC

METER

One circuit operates the hour meter and the

meter

circuit operates on

in

the alternator and supplied to the

the two circuits in a tachometerlhour

and

(-) electrical con-

12

volts

DC

to meter (+)

voltage at tach terminal on alternator to

12

NOTE:

Current model tachometers use a coarse adjustment dial to set the tachometer to the crankshaft pulley rpms. The calibrating screw is then used

COARSE ADJUSTMENT

TACHOMETER

NOTE:

In a new installation having new instrument panels.

the tachometer may not always be correctly calibrated to the engine's rpm. This calibration should be checked installations.

1.

Warm up the engine to normal operating temperature. Remove any specks on the crankshaft pulley with a clean cloth and place a piece pulley to facilitate use

2. Start and idle the engine.

3. Aim the light confirm the engine speed. Check the instrument panel tachometer reading. Adjust the tachometer in the panel by using the instrument coarse adjustment to calibrate the instrument reading to the closest R.P.M. that the photo tach is showing. Then use the fine calibration adjustment bring the instrument to the exact reading

CHECK

of

the tachometer onto the reflecting tape to

for

fine tuning.

TACH

INP

AC

VOLTAGE

(New

Installation)

in

all new

of

suitable reflecting tape on the

of

a photoelectric type tachometer.

as

the photo tach.

TERMINAL

to

Tachometer

1.

Check for proper AC voltage between "tach inp." terminal and (-) terminal.

2.

Check for good ground connection between meter (-) terminal and alternator.

3. Check that alternator is well grounded to engine block at alternator pivot bolt.

Tachometer

a. With a hand-held tach on the front

pulley retaining nut or with a strobe-type tach, read the front crankshaft pulley rpm at idle.

b.

Adjust the tachometer with a small Phillips type screwdriver through the calibration access hole in the rear the tachometer. Zero the tach indicated by the strobe idle and at high speed and adjust the tach as needed).

Sticking

Inaccurate

or

of

the crankshaft

of

and

bring it to the rpm

hand tach. (Verify the rpm at

Engines & Generators

31

ENGINE

ADJUSTMENTS

DRIVE

Proper inspection, service and maintenance is Drive Belts under MAINTENANCE SCHEDULE).

Drive belts must be properly tensioned. Loose drive belts win not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pun the alternator out

wear out prematurely. Excessive drive belt tension can also cause rapid wear coolant pump's bearing. A slack belt or the presence

the belt can cause belt slipping, resulting

temperatures and tachometer variations.

The drive belt

no less than 3/8 inch (lOmm) and no more than

(12mm)

point between the two pulleys on the longest span

A spare belt or belts should always be carried on board.

Adjusting

1.

2.

3.

4. Tighten the base mounting bolt and the adjusting strap

5. Run the engine for about 5 minutes, then shut down and

BELT

ADJUSTMENT

of

the drive belts

important for the efficient operation

of

alignment and/or cause the alternator to

of

the belt and reduce the service life

is

properly adjusted

as

the belt

A

WARNING:

drive

belt's

Loosen the alternator adjusting strap bolt and the base

mounting bolt. With the belt loose, inspect for

edges. Pivot the alternator on the base mounting bolt to the left

or right as required, to loosen

bolt.

recheck the belt tensions.

tension

Belt

is

depressed with the thumb at the mid-

Never

attempt

while

the

Tension

of

your engine (see

in

high operating

if

the belt can be deflected

112

to

check

Dr

adjust

engine

is

in

operation.

wear,

cracks and frayed

or

tighten.

inch

of

the

of

oil on

the belt.

the

FUEL

INJECTOR

HOLOOWN

FUEL

In case injectors checked and overhauled injection service center. loss in injector faults. Since fuel injectors must clean room environment, it

injector as a spare should a problem occur.

Before removing the old injector, clean the area around the

base

falling down into the injector hole.

out easily and is held in by carbon build-up

the injector side-to-side with the aid

free

The injector seats in the cylinder head on a copper sealing

washer. This washer should be removed with the injector and

replaced with a new washer when the new injector

The fuel injectors should be pressure tested after

hours.

INJECTION

NUTS

INJECTORS

of

severe vibrations and detonation noise, have the

by

an authorized fuel

Poor fuel quality, contaminants and

of

positive fuel pressure to the injection pump can result

be

serviced

is

best to carry at least one extra

of

the injector to help prevent any rust

If

it,

and then lift it out.

STARTING HOLDDOWN

PRESSURE

NUTS

TORQUE

2630

psi

13.7 ± 1.5

or

debris from

the injector will not lift

or

the like, work

of

the socket wrench

is

750 operating

(18.1

Mpa)

(185

Kg/em')

It-Ib

(1.9 ± 0.2

in

a

to

installed.

Kg-m)

STARTER

The starter and the alternator should be serviced every 1200 operating hours.

Starter Alternator slip ring cleaning.

Carbon

Refer to your WESTERBEKE SERVICE MANUAL.

AND

ALTERNATOR

commentator cleaning.

brushes

and

the

brush

SERVICE

contact check.

Engines & Generators

32

NOTE:

ments below

ENGINE

WESTERBEKE

be

performed

is

provided

to

ADJUSTMENTS

recommends

by

a competent engine

assist

the

that

mechanic.

the

following engine adjust-

mechanic.

The

information

TESTING

Make certain the oil level (dipstick) and the air intake filter must also be

1.

2.

3.

ENGINE

Warm the engine to normal operating teITiperature. Move the control lever to a position for shutting off the

fuel. (Disconnect the wires is

used).

Remove all the glow plugs from the engine and install the compression gauge/adapter combination to the cylinder on which the compression

COMPRESSION

is

clean. The battery and starter motor

in

good condition.

is

at the correct level

if

a fuel shutdown solenoid

is

to be measured.

MEASURING COMPRESSION

DIAL

GAUGE

OIL

PRESSURE

The engine's oil pressure, during operation,

by

the oil pressure gauge on the instrument panel. During normal operation, the oil pressure will range between 85

psi.

NOTE:

A newly started, cold engine can

reading pressure depending upon

placed

Low

The specified safe minimum oil pressure gradual loss For additional information on low oil pressure readings, see the ENGINE

Testing

To

install a mechanical oil pressure gauge in it's place. After

warming up the engine, set the engine speed at idle and read

the oil pressure gauge.

OIL

SENDER

up

to

85

psi.

A warmed engine can have

reading

on

Oil

Pressure

as

low

as 40 psi.

the

temperature

the

engine,

of

and the RPM's.

oil pressure usually indicates worn bearings.

These

of

the

TROUBLESHOOTING

Oil

Pressure

test the oil pressure, remove the oil pressure sender, then

PRESSURE

AND

SWITCH

15 -20

psi

TORQUE

at

idle

9 -

speed.

13

n-Ib

have

engine,

chart.

(1.2 -1.8

is

indicated

an

readings

the

is

5 -

10

oil

an

psi. A

m -

40 and

pressure

oil

will

vary

load

Kg).

4.

Close the raw water seacock (thru-hull).

5.

Crank the engine and allow the gauge to reach a

maximum reading, then record that reading.

6.

Repeat this process for each cylinder.

COMPRESSION

ALLOWABLE

MAXIMUM

28.44

psi

NOTE:

Jfthe readings

PRESSURE

LIMIT

PERMISSIBLE

(2.0

Kg/em')

are

441

psi

(31.0

370psi

(26.0

DIFFERENCE

below

the

Kg/em')

Kg/em'). BETWEEN

limit,

CYLINDERS

the

at

200

engine

rpm.

needs

overhaul.

7.

Re-install the glow plugs and reset the fuel shut-off run position.

S.

Open the

Low

Compression

When low compression applying a small amount plug hole. Allow the oil to settle.

Install the pressure gauge and repeat the above test. If the compression reading rises dramatically, the fault is with the rings. If the compression valve does not rise, the problem with the valves.

A slight rise

both the rings and the valves.

raw

water

seacock (thru-hull).

is

found, determine the cause

of

oil

in

the cylinder thru the glow

in

compression would indicate a problem with

to

by

an

the

is

PREHEAT

OIL

PRESSURE

SWITCH

SOLENOID

20A

BREAKER

Engines & Generators

33

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided

to

ADJUSTMENTS

assist the mechanic.

VALVE

The valve clearance must hours. or whenever the valve rocker Valve adjustment should only be done when engine Cold engine valve clearance

CLEARANCE

ADJUSTMENT

be

adjusted every 200 operating

is

abnormally noisy.

is

0.0157

in

(0.40 mm).

~..J

~D.D1571N

'D.4DMMI

~VE

~

NOTE:

The head bolts have been tightened with the

"Angular Tightening Method". Therefore, it

to

retighten the cylinder head bolts before adjusting the valve

clearances.

ADJUSTMENT

Chart

shows

Cylinder Valve

arrangement

PROCEDURE

six

cylinder

model

No.

1

I

E I E I E I E I E

~~EARANCE

is

not necessary

2

4

3

5

cold.

CRANKSHAFT

6

I

E

3. After adjusting the valves with piston No. I at rotate the crankshaft 3600 again aligning the TDC mark and the pulley mark. This brings piston TDC, then adjust the remaining valves.

INJECTION

Improper injection timing can cause engine failure. In normal servicing, this check and adjustment

it

might be necessary in conjunction with other related work

such as

PUllEY

TIMING

an

engine overhaul.

CHECK/ADJUSTMENT

in

unnecessary, however,

.........

'~::7'l'---TDC

No.6

IDC,

or

No.4

TIMING

MARKS

MARK

PULLEY

to

MARK

When

No.1

TOC

in

stroke

No.6

in

the

stroke

No.4

four

No.

arrangement

No.1

TDC

in

stroke

No.4

TOC

in

the

stroke

cylinder

the

com-

cylinder

com-

cylinder

the

cylinder

com-

O 0

is

to

the top dead center

piston (four cyl.)is on

model

1

I E

com-

O 0

is

0

No.6

I E I E I

0 0 0

@ @ @ @ @ @

piston (six cyl.)

in

the compression

in

is

in the

IDC

in

No.6

IDC

in the

2 3

4

E

0 0

@ @

@

is

at

pression

When

at

TOC

pression

1.

In

order to bring No. I or piston (four cyl.) stroke, align the TDC mark and the crank shaft pulley mark.

2.

Do the adjustment on the circle marked valves above table where No. I piston compression stroke. After these steps, do the adjustment on the double circle marked valves where the

(six cyl.)

compression stroke.

Chart

shows

Cylinder Valve

I-

When

Z

is

at

=

a::

pression

II.

When at

pression

No.4

the

piston

CHECK

Bring No. 1 piston to the top dead center on the compression stroke. Turn the crankshaft pulley engine front) and align the mark on the crankshaft pulley

with the Remove the access cover at the front

and check the alignment between the pointer injection pump gear lock plate and the projected pointer the timing gear case. is

If they are

the compression stroke. turning the crankshaft pulley one more tum to repeat the procedure to make sure that it

PROCEDURE

IDC

mark.

set correctly.

in

alignment, No. 1 cylinder

INJECTION PUMP MARKS

If

A and B are

If

it

c1ockwi~e

(viewed at

of

the injection pump

A on the

in

alignment, the timing

is

at the TDC on

is

in

misalignment, recheck by

is

in

alignment.

B on

Engines & Generators

34

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust-

ments be

below is provided to assist the mechanic.

Check the crankshaft position for the start

1.

Turn

the crankshaft pulley counterclockwise viewed from pulley mark. The timing mark

the

engine front about 30°. pulley mark indicates the degrees before

2.

Remove No. I high pressure injection line.

1'1

~DELIVERY

e

::-~~~~*-----

3. Remove the injection pump No. I delivery valve holder, delivery valve and spring and reinstall the delivery valve holder back into the pump.

DELIVERY

39 -44

4. Slowly turn the crankshaft pulley clockwise and at the

same time, feed fuel to the injuection pump by slowly pumping the feed pump. When the fuel stops to

from shaft pulley and pumping. This is

injection. .

VALVE

HOLDER

Nm

(4 -4.5

No. I delivery valve holder, stop tut;ning the crank-

TIGHTENING

Kg-m!28.9 -32.5

TORQUE:

ft-Ib)

th~

peiformed

of

fuel injection. 5. Notice which injection timing mark

VALVE

HOLDER

DELIVERY VALVE

beginning

ADJUSTMENTS

by a competent engine mechanic. The information

of

fuel

injection

The degrees before TDC differs depending on the engine model. Refer to the specifications

for

the respective model engine.

do the following adjustment.

flow

of

fuel

out

ADJUSTMENT

1.

Align the pulley mark and the specified timing mark. (Refer

2.

Loosen the four injection pump attachment nuts.

3.

To advance pump drive shaft away from the engine.

To

retard

pump drive shaft toward the engine.

NOTE:

on

the crankshaft pulley correspond

angle.

4.

Recheck the timing, following procedures I through

5. Tighten the four injection pump attachment nuts.

6.

Again remove No. I delivery valve holder, and reinstall the delivery valve, spring and the valve holder.

DELIVERY

39 -44

7.

Reinstall the No. I high pressure injection line.

LOOSEN (80TH

PROCEDURES

to

the injection timing specifications.)

the

timing, pivot the injection pump

the

timing, pivot the injection pump at the

The 1

mm

misalignment between the timing marks

VALVE

HOLDER

Nm

(4 -4.5

FOUR

SIDES)

TIGHTENING

Kg-m!28.9 -32.5

NUTS

is

aligned with the

in

alignment with the

(IDC),

on

the injection timing

If

the timing

to

about r

TORQUE:

ft-Ib)

the start

is

incorrect,

at

in

the

crank

5.

"

PULLEY

MARK

Engines & Generators

35

TIMING CASE

GEAR

HURTH

TRANSMISSIONS

SHIPMENT

For safety reasons, the transmission is not filled with trans- mission fluid during shipment and the selector lever porarily attached to the actuating shaft.

Before leaving the WESTERBEKE plant, each transmission undergoes a test run, with Dextron III The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year

DIPSTICK

OUTPUT

COUPLING --.....

OIL

COOLER

The oil cooler, mounted above the transmission, provides

continuous cooling for the transmission fluid. Raw water passes through the tubes board. The transmission fluid is cooled as it flows around the tubes and back into the transmission.

WESTERBEKE A

SPARE

RECOMMENDS

OIL

COOLER

ABOARD

if

properly stored.

\l:I....e3IN

of

the cooler and discharges over-

CARRYING

ATF

transmission fluid.

~;;iJ#N~k--AIR

~~IJt,

........

is

tem-

VENT

~.JJ--

MODEL

FLUID FIlTER

630

RAW

WATER

CONNECTION

INITIAL

Set the shifting lever to neutral position (N). Start the engine and let it run long enough in idle to with transmission fluid. Shift into gear, forward and reverse; shifting should be smooth and positive. Direct changes from forward to reverse are permissible since the mUltiple clutch permits changing at high rpm including sudden reversing at high speeds in the event

After initial operation, make a visual inspection coupling, oil cooler and hoses, and the cable connections to the transmission.

LOCKING

Locking required: use the gear shift lever position opposite your direction position corresponding to the direction

WHEN

Rotation

boat well as operation (for charging the battery), will have the transmission.

NOTE:

gear shift must be in the neutral position. The propeller idle

DAILY

OPERATION

fill

the cooler and hoses

of

danger.

THE

PROPELLER

of

the propeller shaft by an additional brake

of

travel for this purpose. Never put the gear shift

of

travel

UNDER

of

is

being sailed, being towed or anchored in a river,

When the

and

can free-wheel.

SAIL

OR

BEING

the propeller without a load, such as when the

of

the engine with the propeller stopped

boat

is being sailed (engine stopped), the

TOWED

no

detrimental effects on

OPERATION

disc·

of

the output

is

of

the boat.

in

not

the

as

is

at

o Check the transmission fluid.

o Visually check the gear shift linkage and transmission. o Start the engine in neutral, allowing a few minutes

to warm the fluid.

at

idle

o Shift into gear.

RAW

WATER

CONNECTION

TRANSMISSION

Fill the transmission with Dextron should be up to the mark on the dipstick. After checking the level, press the dipstick into the case and turn it to tighten.

During the first 25 operating hours, inspect the bell housing, output shaft and transmission cooler for leakage. The fluid should be changed after the first 25 hours and every hours thereafter.

NEUTRAL

These transmissions are equipped with a neutral safety switch. This Unless the transmission selector lever is perfectly aligned neutral, the engine starter will not activate.

SWITCH

is

to prevent the engine

TRANSMISSION

FLUID

OIL

COOLER

l/l

ATF. The fluid level

fr<,Jrn

starting

300

in

gear.

in

Engines & Generators

NOTE:

Too

Iowan

idle speed will produce a chattering noise

from the transmission gear and damper plate. In such cases

the idle speed should be increased.

Operating

The operating temperature exceed 176°F connection for a temperature probe output

A

too transmission

Temperature

of

the transmission should not

(80°C) under normal continous running. A

is

provided. At maximum

of

the engine, the fluid may reach 220°F (l04°C).

CAUTION:

high,

stop

If

the

fluid.

the

transmission

engine

immediately

fluid

temperature

and

check

is

the

36

HURTH

TRANSMISSIONS

CHANGING

ACTUATING

LEVER

16mm

(8")

THE

SCREW

TRANSMISSION

O-RINGS

FILTER

ELEMENT

FLUID

MODEL

450

Replacing

Pour in new

with the dipstick.

Transmission fluid quantities will vary with the use ers, length

Reinsert the filter assembly into the housing. Press it and tighten the Allen screw.

NOTE:

screw

After running the engine, shut down and recheck the fluid

A

engine

hole.

the

Fluid

Dextron

of

HURTH 45 - 2.12 quarts (2.0 Liters)

HURTH 63 - 3.2 quarts (3.0 Liters)

Some

transmissions

on

their filter assemblies.

WARNING:

Is

ronnlng.

This

could

1Il

ATF fluid and check the quantity

hoses and the angle

Approximate Quantities

use

a "T" handle

Neller

pull

out

Hot

nuld

will

cause

sell

ere

bums.

of

the transmission.

the

splash

dipstick

from

in

place

while the

of

cool-

in

place

of

a

level.

the

dipstick

MAINTENANCE

Transmission maintenance is minimal. Keep the exterior

housing clean, check the fluid level as part

routine, and change the fluid every Periodically inspect the transmission and the cooler for leaks

and corrosion. Make certain the

checking the fluid level look for signs

(fluid will appear as strawberry cream).

300 operating hours.

air vent is clear and when

of

your regular

of

water contamination

Filter

Element

The Hurth transmission has a filter element located opposite

the dipstick. This filter must be replaced whenever the fluid

changed.

Remove the filter 6mm Allen wrench.

Twist and pull out the filter and remove the element. the new filter onto the cover and lock it into place it clockwise. Check the necessary. Replacement filters can be obtained from your local WESTERBEKE dealer or

Removing

Push a suction pump hose down through the pipe hole (under

the filter) to the bottom

Remove the oil return line from the cooler and allow the oil

to drain into a container, then reconnect the oil return line.

Wipe down the transmission and properly dispose fluid.

the

by

loosening the screw on the cover using a

Place

by

O-rings for damage and replace if

ZF

(Hurth

dealer).

Fluid

of

the housing and suck out the fluid.

of

turning

the used

Lay-upJWinterize

Storage requires special care. Follow these procedures:

D Drain water from the transmission oil cooler and replace

is

with a proper mixture

NOTE:

This

operation will normally occur

engine

raw

water cooling system

D Clean up the transmission and touch up unpainted areas

(use heat resistant paint).

D Fill the transmission with

vent internal corrosion (extended storage only, twelve months

or

more).

D Loosen attaching hardware from the transmission output

flange and propeller shaft coupling flange before ing the boat from the water. Separate the flanges and spray with lubricant.

D Inspect the gear shift cable, linkage, and attachments.

Look for corrosion the conduit, and bending all moving parts.

NOTE:

If

the

transmission

(twelve

months or

fluid

to

prevent internal

before

putting

of

more),

the

engine back

of

antifreeze coolant.

when

the

is

properly

Dextron

the end fittings, cracks or cuts

of

is

1Il

the actuator rods. Lubricate

to

be

stored for a

it should be topped off

corrosion.

Reduce the fluid

into

service.

winterized.

ATF fluid to pre-

remov-

10llg

with

in

time

level

Engines & Generators

37

HURTH

TRANSMISSIONS

CABLE

. The transmission is suitable for a single lever gear shift.

Upon loosening the retaining screw, the actuating lever (see illustration) can be moved to any position required for the control elements (cable or rod linkage). Make certain that the actuating lever does not contact the lever hub: the minimum distance between the lever and

The control cable to tral position should coincide with the neutral position transmission.

Shifting

NOTE:

shift lever travel is sufficient its stop.

CONNECTIONS

hub

should be 0.02in(0.5mm).

or

rod should

the actuating lever when in the neutral position. The neu-

of

the gear shift lever

Positions:

A= Propeller rotation opposite

N= Neutral position

B=

Propeller rotation same as engine rotation.

When shifting to

CABLE BRACKET

"A"

be

arranged at a right angle

on

the control console

of

the lever on the

of

engine rotation.

or

"B"

positions. make sure the

for

the actuating lever to contact

N

SHAn

WESTERBEKE recommends a flexible connection between the transmission and the propeller shaft bly mounted, in order to compensate for angular deflections. The installation required, since the propeller thrust will be absorbed transmission bearing, provided the value specified under SPECIFICATIONS is not exceeded. However, the output shaft should be protected from additional loads. Special care should be taken to prevent torsional vibration. When using a universal joint shaft, make certain to observe the manufacturer's instructions.

Even with the engine solidly mounted,the use

coupling

bearings caused by hull distortions, especially boats coupling and stern gland is less than about

NOTE:

shifting is

or small a bending radius

mount

two threaded holes located

the gear housing. Refer to the WESTERBEKE parts

COUPLINGS

if

the engine

of

a special propeller thrust bearing

or

"DRIVESAVER" will reduce stress

or

where the distance between the transmission output

800mm.

When installing the transmission, make certain that

not

impeded

rod linkage, by unsuitably positioned guide sheaves, too

a support

by

restricted movability

or

other

restrictions.

for

shift control cable connections, use the

on

the cable bracket mounted

In

is

by

of

a flexible

in

the gearbox

in

wooden

of

the cable

order to

list.

is

flexi-

not

the

011

8

ACTUATING

LEVER

A greater amount detrimental and is recommended. However, is shorter, proper clutch engagement might be impeded which,

in

turn, would mean premature wear, excessive heat generation and clutch plate failure. This would be indicated by slow clutch engagement or

CONTROL TROUBLESHOarING)

NOTE:

Check

season.

A

CAUTION:

the

actuating

shift

lever

this

mechanism

transmlsslDn

of

actuating lever travel is in no way

no

engagement at all (see

CABLES

for

travel

under TRANSMISSION

proper actuating lever travel

The

position

lever

Is

from

Is

In

any

wananty

of

factory-adjusted

neutral

will

position

way

tampered

be'

vDld.

the

mechanism

to

to A and

with.

if

ensure

ACTUATING LEVER

LEVER

1-

0.021n

r(0.5mm)

the lever travel

at

least each

behind

equal

B.

If

the

HUB

GEAR

SHIFT

LEVER

For additional information contact:

HURTH MARINE ZF

Industries Marine 3131 Fort Lauderdale, Tel.: (954) Fax: (954) 581-4077

US Headquarters

SW

42nd Street

581-4040

GEAR

FL

33312

TYPICAL

STEERING

STATION

Engines & Generators

38

BORG

WARNER

OIL

COOLER

VELVET

DRIVE

SHIFT

The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly

(F), Neutral ball located behind the transmission lever must work freely to center the lever in each position. the helm must actuating lever through shift mechanism adjustments. An improperly adjusted shift mechanism can cause damage the transmission. The shifting mechanism and transmission actuating lever should be free ensure proper operation.

TRANSMISSION

LEVER

POSITION

in

Forward

(N), and Reverse (R) shifting positions. A detent

The

gear shift positions at

be coordinated with those

of

dirt and well lubricated to

of

the Velvet Drive

to

SHIPMENT

For safety reasons, the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft.

Before leaving the WESTERBEKE plant, each transmission

III

ATF

undergoes a test run, with Dextron

The residual fluid remaining in the transmission after drain-

ing acts as a preservative and provides protection against corrosion for at least one year

TRANSMISSION

Check the transmission fluid level on the dipstick.

transmission has not been filled, fill with Dextron

continue

tion, keep a lookout for any leakage at the bell housing, output shaft and transmission cooler. This fluid should be changed after the first 25 hours and approximately every operating hours thereafter and/or at winter lay-up.

A

to

CAUTION:

and

the

correct

staffing

the

FLUID

use this fluid. During the first 25 hours

Be

ceffaln

slzs

cooler

engine.

if

properly stored.

the

transmission

Is

properly

transmission fluid.

If

the

III and

of

opera-

Is

filled

Installed

before

300

Shifting

Place the gear shift in Neutral before starting the engine. Shifting from one selector position to another selector position may be made at any time below order. speed. allow the transmission fluid to warm up for a few minutes.

Into

Gear

1000 rpm and

Shifts should be made at the lowest practical engine

Start the engine and set the throttle at idle speed;

in

any

Neutral

Move the gear shift lever to the middle position. feel the detent. This centers the actuating lever on the transmission. With the control in this position, hydraulic power is completely interrupted and the output shaft

sion does not tum.

NOTE:

Some transmissions are equipped with a neutral safety switch. aligned in neutral, the engine starter will not activate.

Unless the transmission actuating lever is perfectly

You

of

the transmis-

should

Forward

Move the gear shift lever to the forward position.

The

feel the detent. the forward position. The output shaft and the propeller shaft move the boat in a forward direction.

actuating lever on the transmission

You

should

is

in

Reverse

Move the gear shift lever to the reverse position.

feel the detent. the reverse position. The output shaft and the propeller should move the boat

NOTE:

Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine. Reverse is always away from the engine.

the gear shift control in the forward position, shut engine! This problem of

the actuating lever by the gear shift lever.

The

actuating lever on the transmission is

in

a reverse direction (astern).

If

boat

moves backwards with

may

be

a result

of

incorrect movement

You

off

should

in

the

Engines & Generators

39

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

FORWARD

DAILY

OPERATION

TRANSMISSION

NEUTRAL

AC11JATING

LEVER

REVERSE

POSITIONS

o Check the transmission fluid. o Visually check the gear shift linkage and transmission. o Start the engine

for the fluid to warm.

NOTE:

Too

noise

from

such

cases

in

Iowan

idle

the

transmission

the

idle

neutral. Allow a few minutes at idle

speed will

speed

should

produce a chattering

gear and

damper

be

increased.

plate.

o Shift into gear.

A

CAUTION:

cause

damage

throttle

on

back

the

transmission

Shifting

to

Idle

the

and

gears

engine

when

the

above

damper

shifting

damper

1000

plate.

gears

plate.

rpm

Pulling

will

can

save

the

wear

In

o Clean off the transmission and properly dispose

used fluid.

o Refill the transmission with

quantity will vary depending on the transmission model and the installation angle. Fill through the dipstick hole.

DEXTRON

/II

of

ATF. The

the

D Check the dipstick for the proper fluid level.

D Replace the oil filler

into place and tum clockwise until finger-tight.)

cap

and dipstick. (Press the dipstick

D Run the engine, shutdown and recheck the fluid level.

A

WARNING:

engine

Is

hole.

This

Oil

Capacity

Approximately 2.5 quarts (2.36 liters) sions to the oil level fill have a direct relationship to the oil capacity. Additional oil

will

be required to fill the oil cooler and the cooler lines. The

of

angle

oil required to fill the transmission. .

installation will make a difference

Never

running.

could

cause

Hot

pull

out

the

dipstick

nuld will

severs

mark

splash

bums.

will

on the dipstick. Many variables

Make

____

seal to

the

from

certain

Is

screwed

handle.

fill

in

while the

most transmis-

the quantity

the

tight

the

dipstick

rubber

of

INSPECTION

o Visually check for oil leaks

Check for wear on the hydraulic lines and replace worn.

at

the hydraulic connections.

if

o Lubricate the detent ball and shift cable attachments.

o Inspect the shift linkage. o Inspect the transmission bolts; retorque

A

CAUTION:

sion

shift

plISltlons.

CHANGING

After the initial

be

changed at every 300 operating hours thereafter or at win-

ter haul-out. However, the fluid

becomes contaminated, changes color,

Clutch

fallurs will

lellSr

does

not

fully

THE

TRANSMISSION

50

hour change, the transmission fluid should

engage

must

if

necessary.

occur

If

the

transmis-

the

detent

ball

FLUID

be changed whenever it

or

smells rancid.

o Remove the oil filler cap and dipstick. o Remove the oil cooler return line and allow the oil to

drain into a container.

o Reconnect the oil cooler return line.

D Use a suction pump to remove the transmission oil

through the filler cap/dipstick hole.

OILDIPsnCK

Oil

Temperature

A maximum oil temperature mended. Discontinue operation anytime sump oil tempera-

ture exceeds 2300P (1lO

PRESSURE

An

optional mechanical pressure gauge can be installed the control panel to constantly monitor the pressure transmission fluid. A normal reading at

gear should indicate 95 -

constant.

GAUGE

of

1900P (88°C) is recom-

D

C).

2000 rpm

120 Ib-in2 (6.7 - 8.4 kg-cm

of

in

forward

2

)

at

the

and be

EngInes & Generators

40

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission maintenance is minimal. Keep the exterior

of

housing clean, check the fluid level as part routine, and change the fluid every 300 operating hours.

Periodically inspect the transmission and the cooler for leaks and corrosion. Make certain the air vent is clear and when checking the fluid level look for signs

(fluid will appear as strawberry cream).

your regular

of

water contamination

Lay-up/Winterize

Storage requires special care. Follow these procedures:

o Drain the water from the transmission oil cooler and

replace it with a proper mixture

NOTE:

This

operation will usually occur

raw

water cooling system

of

antifreeze coolant.

when

is

properly winterized.

the

engine

o Clean up the transmission and touch-up unpainted areas

(use heat resistant paint).

o Fill the transmission with Dextron III ATF fluid to pre-

vent internal corrosion.

o Loosen attaching hardware from the transmission

output flange and propeller shaft coupling flange before removing the boat from the water. Separate the flanges and spray with lubricant.

o Inspect the gear shift cable, linkage, and attachments.

Look for corrosion the conduit, and bending all moving parts.

of

the end fittings, cracks

of

the actuator rods. Lubricate

or

cuts in

WARRANTY

Service manuals are available from your dealer.

For assistance, contact:

BORG

200 Theodory Rice Blvd. New Bedford, Tel.: (508) 979-4881

BORG

placed ation

or

Therefore torque loads and directional changes should be

made at low engine speeds. caused by a shock load, any warranty claim

A

CAUTION:

occur resulting BORG related

If

any problems occur with the transmission, see

TRANSMISSION

NOTES

WARNER

MA

WARNER

on

fully reversing

at

WARNER

torsional

is aware

its gears as the result

System-related

low

engine

In

damage

Is

speeds

to

not

vibration

TROUBLESHOOTING

BORG

WARNER

02745

of

the shock loads that can

of

mechanical propeller oper-

of

the propeller blades while shiftIng.

If

it

is

found that a failure was

wiJI

be denied.

noises

or

vibrations

which

can

cause

gear

the

engine

and/or

transmission.

responsible

of

this

for

total

type.

system-

in

this manual.

be

can

rattle

NOTE:

(twelve

fluid

to

before

If

the

transmission

months or

prevent internal corrosion. Reduce the fluid level

putting

the

is

to

be stored for a long

more),

it should

engine back into

be

topped

service.

off

time

with

Engines & Generators

41

TRANSMISSION

TROUBLESHOOTING

CONTROL

The majority

CABLES

of

transmission difficulties arise as a result

of improper clutch adjustments (manual transmissions) or problems with control cables (hydraulic transmissions) rather than from problems with the transmission itself.

HURTH clutches,

in

particular, are very sensitive to improper

cable adjustments.

If

you experience operating problems with the transmission, shut the engine down. First check the transmission-oil level, then have a helper move the cockpit shift lever through the full range - from neutral to full forward, back to neutral, into full reverse, and back to neutral - while you observe the actuating lever on the transmission. to operate, break the cable loose again.

If

it is still stiff, check the cable for kinks

If

the remote

at

the transmission and try

or

exces-

is

stiff

sively tight bends, and check any linkage for binding. A new

cable and perhaps a new linkage mechanism may be needed.

While the cable is loose, shift the transmission in and out gear using the lever on the side

of

the transmission to make

of

sure there's no binding inside the case. If the transmission passes these tests, crank the engine and

have a helper put it in forward and reverse while you observe the propeller shaft; needs professional attention. thrust, check to see you still have a propeller on the end the shaft or, it

isn't

stuck in the

if

the shaft

if

you have a folding

"no

pitch" position.

isn't

turning, the transmission

If

it does tum but there's no

or

feathering propeller, that

of

OIL

COOLERS

The continued flow

time, erode the inside

occur. These internal cooler leaks will cause one

of

raw water through the cooler will,

of

the cooler causing cross leaks to

of

in

the fol-

lowing two problems:

1.

Transmission fluid will leak into the flow

of

raw water

and be discharged overboard through the engine exhaust.

A loss

of

transmission fluid will cause the transmission to

fail.

2. The raw water will leak into the transmission fluid causan

increase in transmission fluid. This contaminated

ing

fluid will appear as strawberry cream.

The transmission

will eventually fail.

Either case requires an immediate response:

1. Install a new oil cooler.

2. Refill the transmission with

If

water has contaminated the fluid, the transmission fluid

DEXTRON

III

ATF.

needs to be cleaned out and replaced with fresh fluid. It will

of

take several fluid changes to get rid

the contamination. Check your dipstick each time until it appears as pure transmission fluid. Change the transmission filter and clean out the fluid lines that connect to the cooler.

If

the transmission fails to shift properly, it will most likely

need the attention

of

a qualified transmission service facility.

A transmission cooler may last ten years or more but, in some circumstances, depending on operating hours, tropical

waters, maintenance, etc. it might only last half that time. WESTERBEKE recommends having a spare cooler aboard.

Transmission

Shifting

pressure

Transmission

Problem

gears

cannot

too

low.

noise

becomes

be

shifted.

louder.

Probable

1.

Shifting Shifting

2.

unattached. Loss

of

3.

4.

Water

Improper

1.

Filter

is

2.

3.

Water Transmission

4.

Air

vent

5.

Fluid

1.

so

that

Damage

2.

to

wear

ment Beginning

3.

mission without transmiSSion,

lever

is

loose.

cable

is

transmission

in

transmission

fluid.

dirty

(if

applicable).

in

transmission

fluid

is

clogged.

level

too

low,

pump

sucks

starting

or

fatigue,

between

engine.

damage

due

to

torsional

fluid,

overload,

or

Cause

broken,

bent

fluid.

too

low.

in

air.

on

flexible

possibly

and

of

bearings

wrong

excessive

or

coupling due

to

misalign-

transmission.

in

trans-

vibrations,

alignment

engine

running

output.

due

of

TIghten

1.

Check

2.

3.

Check Tighten Oil

cooler

4.

Replace compartment, item

2.

1.

Replace Replace

2.

Replace

3.

Add

fluid.

4.

Remove

5.

Top

up

1.

Replace

2.

and

transmission.

Transmission

3.

VerlflcatlonJRemedy

damping

bolt

on

shifting

the

cable,

reattach

or

replace.

for

leaks

at

case

leak -see

cooler

remedy

DEXTRON

filter. oil

cooler -see

painVdirt

fluid

to

flexible

coupling.

needs

transmission bolts.

Check

OIL

COOLER.

(see

OIL

COOLER).

cause.

1/1

ATF.

OIL

from

vent.

marking

on

Check

professional

gear

oil

with

lever.

seal

and

all

oil

hoses

High

Shifting

pressure

COOLER.

dipstick.

alignment

attention.

output

for

water

between

shaft.

leaks.

in

engine

too

low,

see

engine

(continued)

Engines & Generators

42

TRANSMISSION

TROUBLESHOOTING

Chattering mainly

at

low

Transmission fails

to

propel

NOTE:

If

you

Problem

transmission

engine

shifts

the

speed.

into

boat.

noise,

gear,

but

suspect a major problem

The

1.

vibrations a

1.

Output Propeller

2.

Output

3.

propeller

in

your

Probable

engine

or

in

"chattering"

coupling

shaft

coupling

shaft

transmission, immediately contact your WESTERBEKE dealer or authorized marine transmission facility.

Cause

propeller

the

drive

noise

Is

not

is

not

is

tuming.

and

are

turning.

an

generates

unit

which

in

the

transmission.

tuming.

turning.

torsional

produces

Mount a flexible

1.

between a

higher

1.

Transmission

The

coupling

2.

on

the

propeller

pins

and

Inspect

3.

A

folding

Variable

VerlficatlonJRemedy

coupling

with

the

engine

stiffness

needs

bolts

coupling

the

propeller;

propeller

pitch

propeller

and

factor

professional

are

shaft.

bolts

may

another transmission; a coupling might

be

sheared

or

Tighten

or

as

necessary.

it

may

be

missing

be

jammed.

may

be

in

stiffness

sufficient.

attention.

the

coupling

replace

set

or

"no

pitch"

factor

with

is

slipping

screws,

damaged.

position.

keys,

Engines

43

& Generators

LAY-UP & RECOMMISSIONING

GENERAL

Many owners rely on their boatyards to prepare their craft,

including engines and generators, for lay-up during the offseason or for long periods of inactivity. accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own lay-up and recommissioning, or you may use them as a check list if others do the procedures.

These procedures should afford your engine protection during a lay-up and also help familiarize you with the

of

maintenance needs

If

you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than willing to provide assistance.

Propeller

The transmission and propeller half couplings should always be

opened up and the bolts removed when the boat

out

of storage severe strain on the propeller shaft or coupling or both, while the boat shaft has actually been bent apply not

in period of time.

Fresh

A 50-50 solution recommended for use in the coolant system at all times. This solution may require a higher concentration

antifreeze, depending on the area's winter climate. Check the

solution

Should more antifreeze amount from the engine block and add a more concentrated mixture. and mixture cooling system. Now recheck the antifreeze solution's strength.

Shaft

the water or moved from land to water, and during

in

the cradle. The flexibility

is

taken out or put

to

small boats that are hauled out

use, unless they have been dry for a considerable

Water

to

make sure the antifreeze protection

Operate the engine

of

Lubrication

With

the

engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter and fill the sump with

new

oil. Use the correct grade

ENGINE LUBRICATING OIL pages

oil

changing procedure. Run the engine and check for proper

oil

pressure and make sure there are no leaks.

A

CAUTION:

oil

in

the

sump combustion chemicals internal

which

parts.

your engine.

Coupling

Cooling

of

antifreeze and distilled water

the antifreeze concentration throughout the

[Propulsion

in

the water. In some cases, the

by

these strains. This does not

Circuit

be

needed, drain

to

ensure a complete circulation

System

Do

not

leave

over

the

lay-up

deposits

combine

can

reduce

Others prefer to

of

the boat often puts a

of

the water when

an

appropriate

of

oil. Refer to the

in

this manual for the

the

engine's

period.

to

the

Engine produce life

of

your

Engine]

is

hauled

is

of

is

adequate.

old

engine oil

and

harmful

engine's

Fuel

System

Top off your fuel tanks with unleaded gasoline of

higher. A fuel conditioner ·such as STABIL gasoline stabilizer should be added. Change the element gasoline/water separator and clean the metal bowl. Re-install and make certain there are no leaks. Clean up any spilled fuel.

Fuel

System

Top off your fuel tanks with such as control algae and condition the fuel. Care should that the additives used are compatible with the primary filter/water separator used in has one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and allow for 5 system. Check for any leaks that may have been created the fuel system during this servicing, correcting them as

needed. allow movement equipment on the engine.

Raw

Close the through-hull seacock. Remove the raw water intake

hose from the seacock.

gallon bucket

check the zinc anode found

the engine and clean or replace it

any zinc debris from inside the heat exchanger where the

zinc anode

Start the engine and allow the raw water pump

fresh water through the system. When the bucket

stop the engine and refill the bucket with

solution slightly stronger than needed for winter freeze

protection

Start the engine and allow all through the raw water system. the engine. This antifreeze mixture should protect the raw water circuit from freezing during the winter lay-up, as providing corrosion protection.

Remove the impeller from your raw water pump (some antifreeze mixture will accompany it, so catch it Examine the impeller. Acquire a replacement, if needed, and

BlOB

your primary fuel filter/water separator, if the

- 10 minutes to make sure no air

Water

a cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover and gasket.

Cylinder

With the engine running, remove the flame arrester and spray fogging oil into the open air intake. The fogging out the engine as plugs for winter protection.

[Gasoline]

[Diesel]

No.2

diesel fuel. Fuel additiyes

OR and STABIL should be added

in

the system. Change the element

Operating the engine for 5 -

of

the treated fuel through the injection

Cooling

of

is

located. Clean the raw water strainer.

in

your area.

Lubrication

Circuit

Place the end

clean fresh water. Before starting the engine,

in

[Gasoline]

it

coats the valves, cylinders and spark

10

of

the primary heat exchanger on

as

required, and also clean

of

this mixture

Once the bucket

of

89

octane

in

your

at

this time

be

taken

fuel

system

it

to run

is

left

in

the fuel

minutes will help

this hose into a

to

draw the

is

empty,

an

antifreeze

to

be

drawn

is

empty, stop

as

in

a bucket).

oil

will stall

to

fuel

in

five

well

Engines & Generators

44

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication and cleaning able, sure the battery connections are remove the starter. Take care in properly replacing any elec-

trical connections removed from the starter.

Cylinder

If

WESTERBEKE recommends removing fuel injectors for access to the cylinders. Squirt light lubricating oil into the cylinders to prevent the piston rings from sticking to the cylinder walls. Rotate the engine by hand two revolutions then replace the glow plugs

Make sure you have a replacement sealing washer for the injector and fuel line return.

NOTE:

months complete turns every additional 4 months to allow the injection pump components to move. This will help prevent their sticking during extended storage periods.

Intake

Place a clean cloth, lightly soaked in lubricating oil. opening shove the cloth out recommissioning, and an attempt is you may need the assistance note to remove the cloth prior to start-up. exhaust port

Intake

Clean the filter screen in the flame arrester, and place a clean cloth lightly soaked in lube oil around the flame arrester to

block any opening. Also place an oil-soaked cloth through-hull exhaust port. Make a note to remove cloths prior to

Transmission

Check engine sion

its nonnaI

and touch up unpainted areas. flange with an anticorrosion coating,

TRANSMISSION SECTION in this manual for additional

information.

Motor

of

the starter drive pinion

if

access to the starter permits its easy removal. Make

shut

off

before attempting to

Lubrication

you anticipate a long lay-up period (12 months or more)

[Diesel]

the

if

removing the injector

If engine storage is going to be a lengthy one, 12

or

beyond, it is wise to rotate the engine by hand two

Manifold

of

the intake manifold to block the opening.

Manifold

start-up!

or

change fluid in the transmission as required.

is

to be layed up 12 months

to

the very top to prevent corrosion.

at

and

Thru-Hull

of

sight.

(If

can

be blocked in the

[Gasoline]

[Propulsion

recommissioning.

Exhaust[Diesel]

it is not visible at

made

to start the engine,

of

a servicing dealer.) Make a

The

same

manner.

Engine]

or

more, fill the transmis-

Lower

Wipe

off

grime and grease

Protect coupling and output

Refer

is

advis-

glow plugs or

or

injectors.

in

the

Do

through-hull

in

the

If

the

fluid

to the

not

the

to

SPARE

Lay-up time provides a good opportunity to inspect your WESTERBEKE belts spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes. Refer to the

PARTS

engine to see

or

coolant hoses need replacement. Check your basic

SPARE PARTS section

if

external items such as drive

of

this manual.

RECOMMISSIONING

The

recommissioning seasonal lay-up generally follows the same procedures as those described in the section regarding preparation for starting and normal starts. However, some counteracted before starting the engine.

1. Remove any rags that were placed in the exhaust. intake

manifold,

2. Remove the raw water

the old gasket. Install the raw water pump impeller removed during lay-up (or a replacement, if required). Install the raw water

3. Reinstall the batteries that were removed during the lay-

up, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check to make sure that the batteries are fully charged.

4. Remove the spark plugs, wipe clean, re-gap, and install

to proper tightness.

5. Check the condition

circuit and clean

that it is not necessary to flush the antifreeze/fresh water solution from the raw water coolant system. When the

engine

a short period up the heat exchanger ends and clear out any accumulated debris.

6. Check the transmission fluid, during the lay-up, lower the level

or

is

put into operation, the system will self-flush in

[Propulsion

7. Make certain all electrical connections and switches are in the correct position and there are no-loads on the generator at start up.

8. Start the engine described in the

section

of

your

WESTERBEKE

PREPARATIONS FOR STARTING

of

the lay-up procedures will need to be

flame arrester.

pump

cover and gasket and discard

pump

cover with a new cover gasket.

[Gasoline]

of

the zinc anode in the raw water

or

replace the anode as needed. Note

of

time with

no

adverse affects. Also open

if

it had been topped off

of

the fluid to normal.

Engine]

[Generator]

in

accordance with the procedures

PREPARATIONS FOR STARTING

this manual.

engine after a

Batteries

If

batteries are to be left on board during the lay-up period, make sure they are fully charged, and will remain that way, to

prevent them from freezing. the batteries will not remain fully charged, be

subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

If

there exists any doubt that

or

that they will

Engines

45

& Generators

METRIC

CONVERSIONS

INCHES TO MILLIMETERS

Inches

1 25.40 2 50.80 20 508.00 2 0.0787 20 3 76.20 25 635.00 3 4 101.60 30 762.00 4 0.1575 30 1.1811 5

10

mm

127.00 35 889.00 5 0.1969 35

254.00 40

MILLIMETERS

Inches

15

= 1

CENTIMETER,

mm

381.00 1 0.0394

1016.00 100

CENTIMETERS

INCHES TO METERS

Inches

1 0.0254 2 3

4 5 6

TO

CONVERT

Meters

0.0508 8

0.0762

0.1016

0.1270

0.1524 METERS

Inches

10

11

12

TO

CENTIMETERS,

Meters

7 0.1778

0.2032 0.2 7.874 0.8 31.496

9 0.2286 0.3 11.811 0.9 35.433

0.2540 0.4 15.748 1.0 39.370

0.2794 0.5 19.685 1.1 43.307

0.3048 0.6 MOVE

YARDS TO METERS

Yards

1 0.91440 6 2 3 4 3.65760 5

Meters

1.82880 7 6.40080 2 2.18723 7 7.65529

2.74320 8

4.57200

MOVE

DECIMAL

Yards

9 8.22960 4 4.37445 9 9.84252

10

POINT

FOR

Meters

5.48640

7.31520

9.14400 5 5.46807

HIGHER

VALUES -e.g.

MILLIMETERS TO INCHES

mm

10

= 1

Meters

0.1

DECIMAL

Meters

1 1.09361 6

3

Inches

0.1181 25 0.9843

0.3937 40 1.5748

METER = 39.37

METERS

Inches

POINT

METERS

3.28084

6,000

METERS = 6,561.68

TO INCHES

3.937 0.7 27.559

23.622 1.2 47.244 TWO

PLACES

TO YARDS

Yards

mm

15

INCHES

Meters

TO

Meters

8

10

(3.3

FEET)

THE

RIGHT

YARDS

10.93614

Inches

0.5906

0.7874

1.3780

Inches

Yards

6.56168

8.74891

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Ib

1 0.454 2 3 1.361 8 4 1.814 5 2.268

kg

0.907

GALLONS

Gallons

1 3.79 2 7.57 3 11.36 4 15.14

5 18.93

Liters

PINTS TO LITERS

Pints

1 2 3 1.42 8

4 1.89 9 5

Liters

0.47 6

0.95

2.37

32 40 50

I I

0 5

I

10 15

Ib

6 2.722 1 2.205

7 3.175

9

10 4.536

TO

LITERS LITERS

Gallons

10 20 75.71 2 0.53 90 23.77 30 113.57 5 1.32 120 31.32 40 151.42

50 189.28 20

kg kg

3.629

4.082

Liters

37.86

Ib

2 3 6.614 8 17.637 4 8.818 9 19.842 5

4.409 7 15.432

11.023

TO

Liters

1

10

Gallons

0.26 60 15.66

2.64 150 39.62

5.28 180 47.54

kg

6 13.228

10

GALLONS

Liters

Gallons

LITERS TO PINTS

Pints

7 3.31 2 4.23 7 14.79

10

Liters Liters

2.84

3.79 3 6.34 8 16.91

4.26 4 8.45 9

4.73

1

5

Pints

2.11 6 12.68

10.57

Liters

10

TEMPERATURE

60

70

75

85

95 105

140

I I I I I I I I

I I I I I

I

175 212

I I

I

20 25 30 35 40 60 80 100 °C

Ib

22.046

Pints

19.02

21.13

OF

Engines & Generators

46

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) 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

(inJ) x 16.387 = Cubic Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints

(IMP Quarts Gallons Quarts Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

Gallons

(US

MASS-WEIGHT

Ounces

Pounds

(oz) x 28.35 = Grams (Ib) x .454 = Kilograms

PRESSURE

Pounds Inches Inches Inches Inches

Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

Centimeters x .061

pt) x .568 = Liters

(IMP

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

(IMP

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

qt) x .946 = Liters

gal) x 3.785 = Liters

(g) x .035 = Ounces

In

(psi) x 6.895 = Kilopascals

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

(Hg) x 3.377 = Kilopascals (H20) x .07355 = Inches (H20) x .03613 = psi x 27.684 = H20

(H20) x .248 = Kilopascals

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts

(US

Gallons

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kg) x 2.205 = Pounds

(US

(kPa) x .145 = psi

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

3

=in

pt

qt

gal

qt) x .833 = IMP

gal) x .833 = IMP

qt

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers 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-Ib) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(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

Engines

& Generators

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

= ft-Ib

47

80N4

SPECIFICATIONS

Engine

Type

Aspiration

Govemor Bore & Stroke Piston

Displacement

Firing

Order

Direction

of

Rotation

Engine

Torque Compression Dimensions -inches

w/out

Weight

Ratio

transmission

(dry)

TUNE-UP

Compression

(Limit Injector

Valve

Valve (engine

Engine

General

Operating Fresh Raw

Coolant System

Exhaust Exhaust

Pressure

of

difference

Pressure

Seat

Angle

Clearance

cold)

Speed

Temperature

Water

Pump

Water

Pump

(Fresh

Water)

Capacity

Elbow

Hose

Size

ENGINE

Combustion Note:

ment inches

The

pressure

versus

of

water

Air

the

inside

(51

GENERAL

Diesel, Vertical direct

Naturally Integral

4.02 x 4.65 262 1-3-4-2. Clockwise, 210 17:1

(mm)

Height Width: Length:

971

441 Not

2133 Intake

Exhaust Intake

0.Q16 Idle:

Cruise: Max:

COOLING

Fresh controlled

170 Centrifugal Positive

engine-driven.

17

US

EXHAUST

45° 4"

I.D.

AIR

150

differential

mm)

of

the

at

full

between

engine

open

four

cylinder,

in-line

overhead

injection,

aspirated.

with

injection

inches

cubic

inches

when

ft-Ib @ 1500

32.0

25.2

47.2

Ibs

(440.8

kgs).

four-cycle,

80

hp @ 2500

(102.0 x 118.0

(4.3

viewed

rpm.

inches inches inches

valve,

pump.

liter).

from

marine water rpm.

mm).

the

front.

(813

mm) (645mm) (1168

SPECIFICATIONS

psi

(31

kg/cm')

at

200

to

exceed

psi

(150

45°

..

45°.

and

exhaust.

inches

600 -900

1800 -2200

2400

-2500

28.44

kf/cm').

(0.40

rpm.

psi

mm).

rpm.

rpm

(20.0

kg/cm').

SYSTEM

water-cooled

-190° F

displacement,

Qts

with

(77 -88°

type,

(16.1

block.

heat

exchanger.

metal

liters).

thermostatically-

C).

impeller,

belt-driven.

rubber

impeller,

SYSTEM

elbow

(101.6

mm)

hose

REQUIREMENTS

cfm

the

outside

of

the

compartment

throttle

(measure

engine

should

not

exceed

with a manometer).

engine.

cooled

mm)

compart-

2

General

Fuel Fuel

Injection

Fuel

Injection Nozzle Fuel

Filter (on

engine)

Air

cleaner

AirFlow

(engine

combustion)

Fuel

Consumption

Starting

Battery

Capacity

DC

Charging

Starting

Aid Starter DC

No-load

DC

Cranking

General

Oil

Filter

Sump

Capacity

(not

including

Operating (engine

Oil

General

Oil

hot)

Grade

Gear

Ratio

(Standard)

Propeller

Shaft

Propeller

Recommendations

(using

standard

transmission)

Lubricating

Transmission

Capacity

Hurth

FUEL

Pump Timing

ELECTRICAL

A1temator

Current

LUBRICATION

filter)

Pressu

re

TRANSMISSION

Fluid

Sump

45

SYSTEM

Closed

system

No.2

diesel

BOSCH

Model A type

WBTDC

Multi-hole

Full

flow

replaceable.

Replaceable 150

efm.

4.7

U.S.

gph

12

Volt,

(-)

negative 750 -900 51 Glow

12

±

400

Gear Full

14.5

25-85

API SAE

(HURTH helical

clutch.

2:00:1 Right 22x16

propeller rated while

Cold

Amp

rated,

plugs.

Volt, 3 KW.

2%

of

rated

CCA.

type/pressure

flow,

paper

U.S.

QIs

psi.

Specification

30,

10W-30,

Standard

gears,

(Hurth

handed-standard

P-2

blade

should

rpm

(2500 + 000

underway

Dextron

III

2.13

US

qts

with

bleed

oil

(cetane

rating

(In-line).

paper

element.

(17.8

Iph).

SYSTEM

ground.

Cranking

belt-driven.

amps.

SYSTEM

circulation.

element,

(13.8

liters).

CF

or

CG-4,

15W-40.

Transmission)

hydraulically

45A)

or

(Hurth

transmission.

or

22x14

allow

the

-100)

in

forward

(2.0

liters)

approximate.

points.

of

Amps

spin-on

operated

63A)

P-3

engine

at

gear.

45

(CCA).

blade

or

higher).

type.

Case-hardened

multiple

disc

to

reach

its

open

full

throttle

full

Engines & Generators

48

110T 4 SPECIFICATIONS

Engine

Type

Aspiration Govemor

Bore & Stroke Piston

Displacement

Firing

Order

Direction

of

Rotation

Engine

Torque

(max.) Compression Dimensions -inches

w/out

Weight

Ratio

transmission

(dry)

TUNE-UP

Compression (Limit

Injector Valve

Valve (engine

Engine

General

Operating Fresh Raw

Coolant

System

Exhaust Exhaust

Pressure

of

difference

Pressure

Seat

Angle

Clearance

cold)

Speed

Temperature

Water

Pump

Water

Pump

(Fresh Capacity

Elbow' Hose

Water)

Size

GENERAL

Diesel, marine

water

cooled

rpm.

Turbo

charged.

Integral

4.02 x 4.65 202

cubic

1 - 3 -4 -

Clockwise, 280

ft-Ib @ 1500

17:1.

(mm)

Height: Width: Length:

987

Ibs

SPECIFICATIONS

441

psi

Not

to

2133

psi

Intake

Exhaust

Intake

0.016 Idle:

600 -900 Cruise: Max:

2300

COOLING

Fresh

water-cooled

controlled 180

-190° F Centrifugal Positive

engine-driven.

17

US

EXHAUST

45°

elbow

4"

1.0.

four

cylinder,

engine.

Vertical

direct

with

injection

inches

(4.3

2.

when

viewed

rpm.

32.0

inches

28.3

inches

47.2

inches

(448.0

kgs).

(31

kg/cm')

exceed

28.44

(150

kf/cm').

45°

and

exhaust

inches

(0.40

rpm.

1800 -2200

-2400

rpm.

SYSTEM

with

heat

(77 -88°

type,

metal

displacement,

Qts

(16.1

liters)

SYSTEM

(101.6

mm)

four-cycle,

injection,

pump.

(102.0 x 118.0

at

psi

mm).

rpm.

block,

exchanger.

hose

turbocharged

in-line

overhead

110

liter).

from

the

(813 (719 (1168

200

rpm

(20.0

kg/cm').

thermostatically-

C)

impeller,

belt-driven.

rubber

impeller,

valve,

hp @ 2400

mm).

front.

mm) mm)

mm)

General Fuel Fuel

Injection

Fuel

Injection Nozzle Fuel

Filter (on

engine)

Air

cleaner

Air

Flow

(engine

combustion)

Fuel

Consumption

Starting

Battery

Capacity

DC

Charging

Starting

Aid Starter DC

No-load

Current

DC

Cranking

General Oil

Filter

Sump

Capacity

(not

including

Operating (engine

Oil

General

Gear

Propeller Propeller

(using transmission)

Lubricating Transmission

Capacity

Oil

hot)

Grade

Ratio

(Standard) Shaft Recommendations

standard

Fluid

Hurth

FUEL

Closed

No.2 Pump liming

BOSCH

12°

Multi-hole.

Full

Replaceable 230

6.1

ELECTRICAL

12

750 -900

Altemator

Current

51 Glow 12

±

400

LUBRICATION

Gear Full

filter)

Pressure

14.5

25-85

API

SAE

TRANSMISSION

(HURTH helical clutch.

2:00:1 Right

24x18 propeller rated while

Dextron

Sump

45A

2.13

SYSTEM

system

with

diesel

oil

(cetane

Model A type

BTDC.

flow

replaceable.

paper

cfm.

U.S.

gph

(23.1

SYSTEM

Volt,

(-)

negative

Cold

Cranking

Amp

rated,

belt-driven

plugs

Volt, 3 KW

2%

of

rated

amps

CCA.

SYSTEM

type/pressure

flow,

paper

element,

U.S.

Qts

(13.8

psi

Specification

30,

10W-30,

Standard

gears,

hydraulically

(Hurth

45A)

handed-standard

P-2

blade

should rpm underway

US

allow

(2400 + 000

in

III

Qts

(2.0

bleed

pOints.

rating

of

(In-line).

element.

Iph).

ground

Amps

circulation

spin-on

liters)

CF

or

CG-4,

15W-40

Transmission)

operated

or

(Hurth

63A)

transmission.

or

24x16

P-3

the

engine

-100)

forward

liters)

at

gear.

approximate.

45

or

higher).

(CCA)

type.

Case-hardened

multiple

disc

blade

to

reach

open

its

throttle

full

Combustion Note:

ment inches

The

pressure

versus

of

water

Air

the

(51

differential

inside

of

mm)

the

at

full

230

cfm

between

engine

open

the

outside

compartment

throttle

of

should

(measure

the

engine

compart-

not

exceed

with a manometer).

2

Engines & Generators

49

120N6

SPECIFICATIONS

Engine

Type

Aspiration

Governor Bore & Stroke Piston

Displacement

Firing

Order

Direction

of

Rotation

Engine

Torque Compression Dimensions -inches

w/out

Weight(dry)

Ratio

transmission

TUNE-UP

Compression

(Limit Injector Valve

Valve (engine

Engine

General

Operating Fresh Raw

Coolant System

Exhaust

Pressure

of

difference

Pressure

Seat

Angle

Clearance

cold)

Speed

Temperature

Water

Pump

Water

Pump

(Fresh Capacity

Elbow

Hose

Water)

Size

ENGINE

Combustion Note:

ment inches

The

pressure

versus

of

water

Air

the

inside

(51

GENERAL

Diesel, overhead injection,

Naturally Integral

4.13 x 4.92 296

cubic 1-5-3-6-2-4 Clockwise,

298

ft-Ib @ 1500

17:1

(mm)

Height:

Width:

Length: 1175

SPECIFICATIONS

441

psi

Not

to

2631

Intake

Exhaust

Intake

0.016 Idle:

Cruise: Max:

COOLING

Fresh controlled

180 -1900 F Centrifugal

Positive

engine-driven.

25

US

EXHAUST

45° 4"

I.D.

AIR

240cfm

differential

mm)

of

the

at

full

between

engine

open

six

cylinder,

valve,

marine

aspirated.

with

injection

inches

when

32.5

25.2

56.4

Ibs

(534.1

(31

kg/cm')

exceed

psi

(180

45°

and

exhaust

inches

600 -900

1800 -2200

2400

-2500

four-cycle,

fresh

engine.

(105.0 x 125.0

(6.5

viewed

rpm.

inches inches inches

kgs).

28.44 kf/cm').

(0.40

mm)

rpm

water

pump.

liter)

at

200

psi

rpm

cooled

120

from

rpm

(20.0

Vertical

hp

the

(823mm) (645mm) (1410

kg/cm').

SYSTEM

water-cooled

displacement,

qts

with

heat

(77 -880 C)

type,

metal

(23.7

liters)

block,

thermostatically-

exchanger.

impeller, rubber

impeller,

SYSTEM

elbow

(101.6

mm)

hose

REQUIREMENTS

the

outside

of

the

compartment

throttle

(measure

engine

should

not

with a manometer).

in-line,

direct

@2500

rpm.

mm)

front.

mm)

belt-driven.

compart-

exceed

2

General Fuel Fuel

Injection

Fuel

Injection Nozzle Fuel

Filter (on

engine)

Air

cleaner

Air

Flow

(engine

combustion)

Fuel

Consumption

Starting

Battery

Capacity

DC

Charging

Starting

Aid

Starter

DC

No-load

Current

DC

Cranking

General Oil

Filter

Sump

Capacity

(not

including

Operating

(engine Oil

General

Gear Propeller Propeller

transmission)

Oil

hot)

Grade

Ratio

(Standard) Shaft Recommendations

(using

standard

Lubricating Transmission

Capacity

Fluid

Hurth

FUEL

Closed

No.2 Pump TIming

BOSCH

WBTDC Multi-hole Full

Replaceable 240

6.5

ELECTRICAL

12 750 -900

Alternator

Current

51 Glow 12

±2%

400

LUBRICATION

Gear

Full

filter)

Pressure

22

25 -85

API SAE

TRANSMISSION

(HURTH helical clutch.

2:00:1 Right 22x16

propeller full throttle

Dextran

Sump

45

63

2.13

4.2

SYSTEM

system

with

diesel

oil

(cetane

Model A type

flow

replaceable.

paper

cfm

U.S.

gph

(24.6Iph).

SYSTEM

Volt,

(-)

negative

Cold

Cranking

Amp

rated,

belt-driven

plugs

Volt,

3

I<N{

actuated

of

rated

amps

CCA

SYSTEM

type/pressure

flow,

paper

element.

U.S.

qts

(20.8

psi

(3.5 -4.2

Specification

30,

1

OW-3~,

Standard

gears,

hydraulically

(Hurth

45A)

handed-standard

P-2

blade

should

rated

rpm

(2500 + 000

while

underway

/11

US

qts

(2.0

US

qts

(4.0

liters)

bleed

pOints.

rating

of

(In-line).

element.

ground

Amps

shift.

circulation

spin-on

liters)

kg/cm')

CF

or

CG-4,

15W-40

Transmission)

operated

or

(Hurth

63A)

transmission.

or

22x14

P-3

allow

the

engine

-100)

in

forward

liters)

approximate.

45

or

higher).

(CCA)

type.

Case-hardened

multiple

disc

blade

to

reach

its

at

full

open

gear.

Engines & Generators

50

170T6

SPECIFICATIONS

Engine

Type

Aspiration Govemor Bore & Stroke Piston

Displacement

Firing

Order

Direction

of

Rotation

Engine

Torque

(max.) Compression Dimensions -inches

w/out

Weight

Ratio

transmission

(dry)

TUNE-UP

Compression (Limit

Injector Valve

Valve (engine

Engine

General

Operating Fresh Raw

Coolant System

Exhaust Exhaust

Pressure

of

difference

Pressure

Seat

Angle

Clearance

cold)

Speed

Temperature

Water

Pump

Water

Pump

(Fresh Capacity

Elbow Hose

Water)

Size

GENERAL

Diesel, marine fresh

water

2500

rpm. Turbocharged. Integral

4.13 x 4.92 423

cubic 1-5-3-6-2-4 Clockwise, 423

ft-Ib @ 1800 17:1

(mm)

Height: Width: Length:

12451bs

SPECIFICATIONS

441

psi

Not

to

2631 Intake

Exhaust Intake

0.016 Idle:

600 -900 Cruise: Max:

2400

COOLING

Fresh

controlled 180

-190° F

Centrifugal

Positive engine-driven.

25

US

EXHAUST

45°

elbow

4"

1.0.

six

cylinder,

engine.

Vertical

cooled

with

injection

inches

(6.5

when

viewed

rpm.

33.5

28.0

57..5

(565.23

kgs).

(31

kg/cm')

exceed

28.44

psi

(185

kf/cm').

45°

and

exhaust

inches

(0.40

rpm

1800 -2200

-2500

SYSTEM

water-cooled

with

heat

(77 -88°

type,

metal

displacement,

qts

(23.7

liters)

SYSTEM

(101.6

mm)

four-cycle,

direct

(105.0 x 125.0

inches inches inches

mm)

rpm

block,

hose

turbocharged

in-line

overhead

injection,

pump.

liter)

from

the

(823 (711

(1410mm)

at

200

rpm

psi

(20.0

kg/cm')

rpm

thermostatically-

exchanger.

C) impeller, rubber

impeller,

valve,

170

hp

@

mm)

front.

mm) mm)

belt-driven.

General Fuel Fuel

Injection

Fuel

Injection Nozzle Fuel

Filter (on

engine)

Air

cleaner

Air

Flow

(engine

combustion)

Fuel

Consumption

Starting

Battery

Capacity

DC

Charging

Starting

Aid

Starter

DC

No-load

Current

DC

Cranking

General

Oil

Filter

Sump

Capacity

(not

including

Operating (engine

Oil

General ened

Gear Propeller Propeller

(using transmission)

Transmission

Oil

hot)

Grade

Ratio

Shaft

Recommendations

standard

Lubricating

Capacity

Hurth

(Standard)

Fluid

FUEL

Closed

No.2 Pump TIming

BOSCH

12°

Multi-hole

Full

Replaceable 365

9.3

ELECTRICAL

12 750 -900

Alternator

51 Glow

12

±

Current

400

LUBRICATION

Gear Full

filter)

Pressure

22

25-85

API

SAE

TRANSMISSION

(HURTH helical disc

2:00:1 Right 24x18

propeller full throttle

Dextran

Sump

63

4.2

SYSTEM

system

with

diesel

oil

(cetane

Model A type

BTDC

flow

replaceable.

paper

cfm.

U.S.

gph

(35.2

SYSTEM

Volt,

(-)

negative

Cold

Cranking

Amp

rated,

belt-driven

plugs

Volt,

3

I<m

2%

of

rated

amps

CCA

SYSTEM

type/pressure

flow,

paper

element,

U.S.

qts

(20.8

psi

Specification

30,

10W-30,

Standard

gears,

hydraulically

clutch.

(Hurth

45A)

handed-standard

P-2

blade

should

rated

rpm

(2500 + 000

while

underway

III

US

qts

(4.0

liters)

bleed

points.

rating

of

(In-line).

element.

Iph).

ground

Amps

circulation

spin-on

liters)

CF

or

CG-4,

15W-40

Transmission)

operated

or

(Hurth

63A)

transmission.

or

24x16

P-3

allow

the

engine

-100)

in

forward

approximate.

45

or

higher).

(CCA)

type.

Case-hard-

multiple

blade

to

reach

at

full

gear.

its

open

Combustion Note:

ment inches

The

pressure

versus

of

water

Air

the

differential

inside

(51

mm)

of

the

at

365

between

engine

full

open

cfm

the

compartment

throttle

outside

of

the

should

(measure

with a manometer).

engine

not

exceed

compart-

2

Engines & Generators

51

SUGGESTED

SPARE

PARTS

CONTACT

YOUR

WESTERBEKE

DEALER

MARINE

FOR

DIESEL

ADDITIONAL

ENGINES

SUGGESTIONS

AND

INFORMATION

FUEL

FILTERS

I

, i

::

FUEL

STRAINER

The

red 18" handles,

and

long

with a full and a carrying

black

duffel

zipper,

bag

dual

strap.

OIL

FILTERS

is

'-,

-,

:./(\

"":,.,./

'

~

WESTERBEKE Kit A has

offers

the

basic

Kit

A

Impeller Heat

Exchanger

Fuel

Filter

Oil

Filter

Drive

Belts Zincs Thermostat

Engines & Generators

Spare

spares.

Gasket

TRANSMISSION FILTER

HARDWARE

J:P~~

~

SPARE

Parts

Kits

Kit B is

PARTS

in

two

for

more

KitB

Impeller Heat Fuel

Oil

Drive

Zincs Thermostat

Complete Injector Air Transmission

Filter

KITS

versions

complete

Exchanger

Filter

Belts

Gasket

Filter

(separate)

KIT

each

for

Gasket

Filter

packaged

offshore

Kit

THERMOSTATS AND

GASKETS

in a canvas

cruising.

duffel

bag.

52

Engines & Generators

1041WM/DW612000

Westerbeke 80N4, 110T4, 120N6, 170T6 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual