Westerbeke 44bB-35 D THREE, 44A FOUR, 35C THREE, 448 FOUR, 35D THREE Operator's Manual

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OPERATORS

FOR

44A

FOUR -35C

AND

",,'

MANUAL

THE

THREE

THE

448

MARINE

FOUR

DIESEL

PUBLICATION NO. 44180

2nd Edition I October 2001

WESTERBEKE

MYLES

STANDISH

WEBSITE:

AII'Il

WWW.WESTERBEKE.COM

M.mber Nali01llll MIlI'iM

-350 ENGINES

CORPORA

TION • 150

INDUSTRIAL

M(IIIufOClu,..,..

JOHN HANCOCK

PARK·

TAUNTON

Ar.ociDlion

THREE

ROAD

MA 02780

CALIFORNIA

PROPOSITION

Diesel

engine

of

its

constituents

the

State

cancer,

birth

reproductive

A

65

exhaust

of

California

defects,

WARNING

and

some

are

known

and

harm.

to

cause

other

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

IF

GET seek until

gasses

gas. can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

and

include:

and

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY. down

repaired.

ANY

the

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

odorless

and

can

cause

Monoxide

Temples

Coherently

THESE

SYMPTOMS,

symptoms

do

not

and

persist,

restart

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety caused by failure to follow fundamental rules tions. Know when dangerous conditions exist necessary precautions to protect yourself, your personnel, and

your machinery.

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 in place.

• Shut off electrical power before accessing electrical equipment.

• Use insulated mats whenever working on electrical 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 or checking the coolant.

manual

ELECTRIC

is

Lethal

voltage

if

this procedure

BURNS -HOT

system

of

an engine overheat, allow the engine to cool

carefully. Most accidents are

and

Yacht Council (ABYC) standards.

SHOCK

00

not

touch

AC

electrical

running,

or

when

is

present

is

not followed.

connected

at

these

ENGINE

00

not

touch

hot

engine

components. A running

Steam

can

cause

engine

injury

and

connections

connections!

parts

or

and

precau-

take the

to

shore

or

gets

death!

PREVENT

A

• Prevent flash fires. Do not smoke or permit flames or sparks to occur near the carburetor, fuel line, filter, fuel pump, or other potential sources 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 or permit flames or sparks to occur near

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

• 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 fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out

• Do not

• Shut off the fuel service valve at the engine when the fuel system. Take care in catching any fuel that might spill. sources of ing. Ensure proper ventilation exists when servicing the fuel 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

• Make sure a fire extinguisher properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment.

BURNS -FIRE

WARNING:

Use a suitable container to catch all fuel when

Fire

can

cause

injury

or

death!

of

spilled fuel or fuel

of

debris to minimize the

of

fire. Wipe up all spilled fuel and engine oil.

BURNS -EXPLOSION

WARNING:

or

death!

of

the reach

fill

DO NOT allow any smoking, open flames, or other

of

leaks.

Explosions

of

children.

the fuel tank(s) while the engine

fire

near the fuel system or engine when servic-

from

fuel

vapors

can

Open and ventilate cabin

is

installed nearby and

cause

running.

serviCing

is

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 reinstalled before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing.

• Never connect the negative

(+) connection terminal

tive not test the battery condition by shorting the terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery is

being charged.

• Avoid contacting the tenninals with tools, etc., to prevent burns or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.

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

BATTERY

STARTING

Accidental

EXPLOSION

Battery

of

explosion

explosive gases.

ACID

starting

(-)

can

cause

of

the engine before

can

cause

injury

battery cable to the posi-

of

the starter solenoid. Do

To

avoid sparks, do not

injury

TOXIC

• Ensure that the exhaust system

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

• In addition to routine inspection

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

• Do not use copper tubing in diesel exhaust systems. Diesel

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not as toxic as

AVOID

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.

install a carbon monoxide detector. Consult your boat builder or dealer for installation

tional infonnation on Carbon Monoxide).

A

WARNING:

odorless

nausea

gas.

or

death!

fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration tubing resulting in exhaust/water leakage.

through portholes, vents, or air conditioners. 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 gas is present in diesel exhaust fumes. Some toms or signs are:

Vomiting Muscular twitching Dizziness Intense headache Throbbing in temples Weakness and sleepiness

MOVING

GASES

Carbon

monoxide

Carbon

Inhalation

of

monoxide

produces

carbon monoxide inhalation or poisoning

(CO)

is a deadly

is

adequate to expel gases

Pay close

of

the exhaust system,

of

approved detectors.

(CO)

is

an

invisible

flu-like

symptoms,

If

of

PARTS

gas!

of

copper

the engine

the symp-

A

WARNING:

severe

injury

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which If

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.

Sulfuric

or

death!

acid

in

batteries

can

cause

is

destructive.

A

WARNING:

or

death!

• Do not service the engine while it is running. tion arises in which it operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components.

Engines & Generators

i i

Rotating

is

parts

can

cause

injury

absolutely necessary

If

a situa-

to

make

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces or bracelets that

could be caught in moving parts.

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

•

Do

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

the engine is operating.

• Stay clear when the engine is running; hair and clothing can easily be caught in these rotating parts.

HAZARDOUS

A

WARNING:

of

the drive shaft and the transmission coupling

NOISE

High

noise

levels

can

cause

hearing

loss!

• Never operate an engine without its muffler installed.

•

Do

not run an engine with the air intake (silencer)

removed.

•

Do

not run engines for long periods with their enclosures

open.

A

WARNING:

mentally

Dr

Do

not

physically

work

on

machinery

incapacitated

by

fatigue!

when

you

are

ABYC,

INSTALLING

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

ABYC "Safety Standards for Small Craft"

Order

NFPA "Fire Protection Standard for Motor Craft"

Order

USCG "USCG 33CFR183"

Order

NFPA

AND

USCG

PUBLICATIONS

DIESEL

(American Boat and Yacht Council)

from:

ABYC 3069 Solomon's Island Rd. Edgewater,

from:

NFPA

11

Tracy Drive Avon Industrial Avon,

from:

U.S. Government Printing Office Washington, D.C. 20404

MD

(National Fire Protection Association)

MA

02322

(United States Coast Guard)

ENGINES

21037

Park

FOR

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.

ENGINE

Preparations to install an engine should begin with a thorough examination (ABYC) standards. These standards are a combination sources including the USCG and the NFPA.

Sections

H-2 Ventilation P-l P-4 Inboard engines E-9 DC Electrical systems

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

MANUAL

the preceding safety tips and warnings are repeated

INSTALLATIONS

of

the American Boat and Yacht Council's

of

the ABYC standards

Exhaust systems

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

Strict 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 is close to or will be below the vessel's waterline, provisions must be made to install a siphonbreak in the raw water supply hose to the exhaust elbow. This hose must be looped a minimum

the exhaust manifold injection 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

EXHAUST

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

of

20" above the vessel's waterline. Failure to use a siphon-break when

A siphon-break

Failure

damage.

Consult

SYSTEM

the vessels hull.

A

detailed diesel, dealer.

engines

requires

to

properly

40

page

port

is

at

or below the load waterline will result in

and

possible flooding

of

the water-injected exhaust elbow relative

periodic inspection

maintain

the

siphon-break manufacturer for proper

Marine

and

generators,

a siphon-break

Installation

is

available

and

Manual

from

of

the boat.

cleaning

can

result

covering

your

WESTERBEKE

install a

to

ensure

in

catastrophic

maintenance.

gasoline

proper

and

Engines

iv

& Generators

TABLE

Parts

Identification

Introduction

Warranty Procedures ...................................... 3 Alternator Troubleshooting ......................... 25

Serial Number Location ............................... .4 Battery ......................................................... 26

Control

Admirals Panel .............................................. 5

Captains Panel ............................................... 6

Diesel

Oil Pressure ................................................... 7

Preparations

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

Panels

Fuel,

Engine

for Starting/Stopping Warning

Engine

The

Lights,

Break-in

Daily

Operation

RPM's Guide ............................................... 12

Maintenance Cooling

Fuel

Engine

System

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

Raw WaterPump ..........................................

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

Air Intake/Silencer .......................................

System

Fuel Lift Pump .............................................

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

. Fuel Water Separator ..... : .............................

Clow Plugs ................................................... 20

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

Lubricating

Oil Change ...................................................

Oil Pressure ................................................. 22

Remote Oil Filter. ........................................ 23

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

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

Oil

and

Initial

Start-Up .........................

Procedure

Alarms

and

Engine

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

Circuit

Coolant..

Breaker

Procedure ...............................

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

Schedule

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

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

Oil

......

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

.....

....

. 12

OF

CONTENTS

2 3

5

Water DC

Heater

Electrical

Wiring Diagrams/Schematics ......................

Engine Tachometer

7

8

9

10

11

13

15

16 16 17 18

19 19 19 16

Engine

Testing Engine Compression ....................... 35

Fuel Injectors ............................................... 35

Valve Adjustments ....................................... 36

J.S.

and

Borg

Warner

Hurth

PRM

HBW

Newage

Transmission

Propeller

L U

ay-p an

44

Four

35

Three

44

Four Standard Sealants Standard Suggested

21 21

Spare

Parts

European

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

System

Troubleshooting

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

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

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

Adjustments ...........................................

B.W.

Transmission

Velvet

Drive

Transmission

Transmissions Troubleshooting

Recommendation

dR···

ecommlsslonmg

Engine

and

&

Specifications

35

Three

Hardware

........

Lubricants

and

Metric

Spare

Parts

Kits

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

Maritime

Conversion

Council

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

Transmission

...........

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

...

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

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

Chart..

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

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

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

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

Torque

Specifications

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

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

Data

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

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

Registration

..45

..48

...

.........

24

.25

27

31 33 34

37

39

.42

.47

.49 .51

52

53

54 54

55

56 56

57

Engines & Generators

1

PARTS

IDENTIFICATION

44A

FOUR/35C

THREE

20ACIRCUIT BREAKER

REAR

WATER

INJECTED

EXHAUST

ELBOW

RIGHT

\

SIDE

ZINC ANODE

OIL

FILTER

COOLANT

OIL

COOLER

PRESSURE

CAP

SIDE

THERMOSTAT ASSEMBLY

WATER

HEATER

CONNECTION

FRONT

OIL

FILL

DC

ALTERNATOR

RAW

WATER

UNIT

I.D.

FRONT

PUMP

PLATE

START

OIL

FILL

MOTOR

LEFT

AIR

INTAKE/AIR

SIDE

FILTER

PREHEAT

ATFDRAIN

SOLENOID

FUEL

FILTER

REAR

Engines & Generators

INTRODUCTION

This WESTERBEKE Diesel Engine WESTERBEKE's technology. dependable performance of our engines Thank

you

In

order

to important that manual

ual out. nearest WESTERBEKE dealer

This

provided WESTERBEKE

equipment, contact your WESTERBEKE dealer WESTERBEKE'S installation

is

designed

carefully

Should your engine require servicing, contact your

is

your operators

and

WARRANTY

Your

WESTERBEKE

folder.

If,

after

form

you

have registering your writing serial number

with

Customer

'~/WESTERBEKE

Customer Identification MR.

ENGINE MAIN STREET HOMETOWN, Model

35C

Expires

10/16/98

long

years of experience and advanced

We

take

great pride

for selecting WESTERBEKE.

get

the

full

use

and

you

operate and maintain it

to

help

you

and

observe

a technical

dealer.

all

the safety precautions through-

manual. A parts

manual

If

you

PROCEDURES

Warranty

60

days

of submitting the

not

received a customer identification card

warranty,

model

and

commission

please contact

information, including

Identification

,

OWNER

USA

THREE

is

a product of

in

the

superior durability

and

generators.

benefit from your

correctly.

do

this.

Please

for

assistance.

catalog

is

available

are

planning

manual.

is

included

date.

to

in

Warranty the

factory

the

Card

Ser.

#UOOOO-D802

from

engine,

This

read

this

is

also

your

install

this

for

a separate

Registry

in

engine's

and

it

is

man-

PRODUCT

Product software, (technical data, parts lists, brochures and catalogs), provided WESTERBEKE

WESTERBEKE CONTENT

RANTIES OR REPRESENTATIONS WITH RESPECT

THERETO, INCLUDING ACCURACY, COMPLETENESS BE

liABLE INCURRED OF

THE FURNISHING OR USE

WESTERBEKE customers should keep span and

the product software. WESTERBEKE products, whether other suppliers, must sively not

only representatives of WESTERBEKE or be

consulted

product software being consulted

NOTES,

As

this maintenance schedules, engine, critical information CAUTIONS,

NOTE:

A

observed, your

SOFTWARE

manuals,

from

sources other

are

not within WESTERBEKE's

CANNOT

OF

SUCH

FOR

ANY

IN

CONNECTION WITH OR ARISING

between printings of WESTERBEKE product software

unavoidable existence of earlier

The

as

the

definitive authority

makes

good sense but

to

determine

CAUTIONS

manual

An

CAUTION:

takes

and

WARNINGS.

operating procedure essential to note.

Procedures

can

result

BE

RESPONSIBLE FOR THE

SOFIWARE, MAKES NO WAR-

TIMEliNESS

THEREOF

product software provided

not

AND

you

AND

WILL

TYPE

OF

DAMAGE

OF

SUCH SOFIWARE.

from

and cannot

the

be

on

the

is

imperative

accuracy

by

the

relied

respective

the

and

WARNINGS

through

and

in

the

operating procedures,

troubleshooting of your

will

be

highlighted

An explanation

which,

if

damage

or

in

WESTERBEKE

supplier

customer.

not

destruction

engine.

control.

IN

NO

EVENT

OR INJURY

mind

the

time

with

upon

exclu-

product.

that

appropriate

in

currentness of

marine

by

NOTES,

follows:

strictly

than

OR

OUT

or

It

question

the

of

The WESTERBEKE engine serial number

meric

number that ufacture of your WESTERBEKE date

code

is consists of a character followed acter indicates D=1990s), and manufacture.

the

second

can

assist

in

determining

placed

at

the

end of

the

by

the

decade (A=1960s, B=1970s,

first

number represents

and

third

numbers

engine.

engine serial number

three

represent

is

The

numbers.

the

year

an

alphanu-

the

date of

manufacturer's

The

char-

C=1980s,

in

the

decade,

the

month

of

A

WARNING:

lowed,

can

man-

and

Engines & Generators

3

Procedures

result

in

which,

personal

injury

if

or

not

properly

loss

of

fol-

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 can also be found stamped into the engine block to enter this information on the illustration shown below, as this will provide a quick reference when seeking technical information and/or ordering repair parts.

C2¥ii4il

o

•

UNDERSTANDING

The diesel engine closely resembles the gasoline engine, . since the mechanism is essentially the same. The cylinders are arranged above a closed crankcase. 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 maintenance lubricating filter elements must be replaced at the time periods specified, and frequent checking for contaminants (water, sediment, etc.) in the fuel system is also essential. Another important factor is the consistent use high detergent diesel lubrication oil designed specifically for diesel engines.

The diesel engine does differ from the gasoline engine, however, in its method carburetor and ignition systems are replaced by a single component - the fuel injection pump - which performs the function

NUMBER

LOCATION

of

the engine's manifold.

just

above the injection pump. Take the time

of

the nameplate

:143i

MODEL

of

..

SPEC

THE

of

valves, camshaft, pistons, connecting

the fuel, lubricating and cooling systems. Fuel and

of

both.

AVO.

MA

USA

DIESEL

of

handling and firing

ENGINE

of

SER.NO..

The

crankshaft is the

the same brand

of

fuel. The

of

0

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. You must provide us with this information so we may properly identify your engine. In addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). Insist upon WESTERBEKE packaged parts because

not made to the same specifications as original equipment.

SPARES

Certain spares will be needed to support and maintain your WESTERBEKE engine. Your local WESTERBEKE dealer

will assist you in preparing an inventory the

SPARE

sories, see WESTERBEKE's

PARTS

will fit or generic parts are frequently

AND

ACCESSORIES

PARTS

page in this manual. For engine acces-

of

spare parts. See

ACCESSORIES brochure.

Engines & Generators

4

ADMIRAL

DESCRIPTION

This manually-operated control panel KEY

switch

and

RPM

gauge with

meter which measures the engine's running time

1110

hours.

in ATURE Fahrenheit,

engine's oil pressure control circuit tem's

voltage. switch is

in operation.

pushbuttons, one for

RPM

GAUGE:

TERS

REVOLUTIONS

PER

MINUTE

ENGINE

AND RECALiBRATED ACCURACY REAR

OFTHE

The panel also includes a

gauge which indicates water temperature

an

OIL PRESSURE gauge which measures the

in

pounds per square inch, and a

is

turned

VOLTAGE

All

gauges are illuminated

on

The

gauge which measures the sys-

and

remain illuminated while

panel also contains two rubber-booted

PREHEAT

WATER GRADUATED

ILLUMINATED TURNED TEMPERATURE

REGIS·

OF

THE

CAN

BE

FOR

FROM

THE

PANEL.

is

equipped with a

an

ELAPSED TIME

WA1ER

when

and one

TEMPERATURE

ON.

IN THE

for

DEGREES

WHILE

ENGINE'S

IS

170·

in 1EMPER-

in

the

START.

GAUGE:

THIS

FAHRENHEIT

THE

KEY

SWITCH

NORMAL

-190· F (n· -

hours and

degrees

DC

key

engine

GAUGE

AND

IS

OPERATING

88·C).

CONTROL

When

PANEL

the

engine the water temperature gauge will continue temperature reading indicated

was

turned

the

key

switch

once again register the engine's true temperature

pOVl:'er

alarm

Panel.

The

the

buzzer

harness.

in a location to

the

The

buzzer

should

silence

oil

pressure rises

IS

power when will electrical

A

separate Admiral necting

electrical

the

buzzer

be

audible running. on

and engine's

is

shut

down

with

by

off

The oil pressure gauge

is

turned

off

is

restored to the

buzzer

with

harness

installer

to

The

operator

will

the

four-pin

installer

where

should

sound

when

is

responsible is

it

will

when

the

engine

above

OIL

PRESSURE

ATED

IN

POUNDS ILLUMINATED ON.

THE

ENGINE'S PRESSURE (2.1 -4.2

RANGES

kg/em').

the

key

switch

turned

to

register

the

the gauge before electrical

will

fall

to

The temperature

gauge

when

gauge.

is

supplied

connection

also

responsible

be

dry

it

sound

the

has

15

psi

(1.1

GAUGE:

THIS

PER

SQUARE

WHILE

THE

NORMAL

BETWEEN

for

electrically

on

the

and

where

while

the

ignition

started

kglcm

GAUGE

INCH

KEY

SWITCH

OPERATING

30 -60

with

engine's

for

engine

key

and

2

).

IS

(PSI)

psi

every

installing

it

is

turned

the

GRADU·

AND

IS

TURNED

OIL

off,

last zero

con-

will

is

IS

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

SOLENOID

PRESSURE

BUTTON

THE

EXCITER,

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

START

OPERATE

liFT

PUMP,

BYPASSES

IN

ADDITION,

BUTTON.

ENERGIZES

CRANKS

ELECTRICALLY

IS

PRESSED

ENERGIZES

PUMP,

AND

THE

ENGINE'S

THE

ENGINE.

THE

THIS

THE

AND

HELD

__

-1\,,,

SWITCH:

POWER INSTRUMENT

CLUSTER.

~

•

,

~

..

,':

.

-.-

•. :

..

AUTOMATIC COOLANT

SUPPliED REACHES ALARM

Oil LOCATED THE FALL

ING

SIGNAL.

ALARM

TEMPERATURE

WITH

210· F (gg·C),

WHICH

WILL

PRESSURE

ENGINE'S

THE

OFF

TO 5 -10

ALARM.

ALARM:

THE

OIL

psi

SYSTEM

ALARM:

THE

INSTRUMENT

THIS

EMIT

A

AN

OIL ENGINE'S PRESSURE.

(0.4 -0.7

IN

THIS

EVENT,

AN

ALARM

PANEL.

SWITCH

WILL

CONTINUOUS

PRESSURE

OIL

GALLERY.

SHOULD

THE

THE THE ALARM

kg/em'),

BUZZER

IF

THE

ENGINE'S

CLOSE

SIGNAL. ALARM

THIS

SWITCH

ENGINE'S

SWITCH

WILL

DC

VOLTMETER:

INDICATES

.BATTERY

SHOULb

HAS

SOUNDING

SWITCH

OIL

WILL

EMIT

PROVIDES

ONLY

TO PANEL

THE

AMOUNT

IS

BEING

SHOW

13V

BEEN

COOLANT

THE

IS

MONITORS

PRESSURE

CLOSE

SOUND-

A

PULSATING

THE

CHARGED.

TO

14V.

Engines. & Generators

'5

DESCRIPTION

This manually-operated control KEY

switch,

tons,

an lamps, OIL

PRESSURE,

lEMPERATURE.

RPM

GAUGE:

PER

MINUTE

RECALIBRATED

THE

REAR

an

RPM

INSTRUMENT

one

for

ALlERNATOR

and

REGISTERS

OF

FOR

OF

THE

ENGINE

ACCURACY

PANEL.

REVOLUTIONS

gauge,

1EST button

one for

AND

CAN

FROM

panel

is

equipped

PREHEAT

and

DISCHARGE,

high

ENGINE

BE

CAPTAIN

with

and

START

three

indicator

one

CONTROL

a

but-

for

low

COOLANT

PANEL

The

panel

also PRESSURE RPM and

remains

ALARM:

BELOW 5 -10

PULSATING

TEMPERATURE 210°F

(99°C).

NOTE:

THE SOUNDING PRESSURE

gauge

THE

ALARM

SIGNAL.

IN

ALARM

IS

NORMAL.

REACHES

or

is

illuminated

psi

IN

THIS

includes

high

COOLANT

illuminated

WILL

SOUND

(0.4 -0.7 THE

kg/em').

THE

ALARM

FRESHWATER

EVENT,

SOUND ONCE

15

psi

THE

(1.1

WILL

an

alarm

when

while

IFTHE

WILL

ALARM

WHEN

THE

ENGINE

kg/em'),

buzzer lEMPERATURE.

the

KEY

the

engine

ENGINE'S

EVENT,

SOUND

CIRCUIT

WILL

EMIT

KEY

SWITCH

STARTS

ALARM

OIL

AND

IN

THIS

ALSO

COOLING

THE

for

low

OIL

switch

is

in

operation.

PRESSURE

THE

ALARM

IF A

WILL

TEST

PRESSED,

ALTERNATOR,

PRESSURE, COOLANT

TURE

CUITS.

THE

OIL THE TURE

LIGHTS ADDITION

ING

BUZZER.

WILL

THE

COOLANT

RISES

TO

CONTINUOUS

IS

TURNED

THE

ENGINE'S

SILENCE.

BUTTON:

TESTS

AND

TEMPERA-

CONTROL

WHEN

ALTERNATOR,

PRESSURE,

WATER

TEMPERA-

INDICATOR

ILLUMINATE

TO

THE

ALARM

The

turned

on

FALLS

EMIT

A

SIGNAL.

ON.

THIS

OIL

WHEN

THE

OIL

THE

CIR-

PRESSED,

THE

AND

IN

SOUND-

START

BUTTON: STARTER'S BUTTON PREHEAT TIME.

SOLENOID

WILL

BUTTON

WATER ALARM

WHEN

NOT

OPERATE

IS

TEMPERJlTI

LIGHT

PRESSED,

WHICH

CRANKS

ELECTRICALLY

PRESSED

AND

ENERGIZES

THE

HELD

THE

ENGINE.

UNLESS

AT

THE

THIS THE

SAME

Engines, & Generators

~---

PREHEAT

BUTTON: ALTERNATOR'S SOLENOID GLOW SURE GIZES

ON

PLUGS,

ALARM

THE

START

EXCITER,

THE

AND

SWITCH.

WHEN

PRESSED,

THE

INJECTION

BYPASSES

IN

ADDITION,

BUTTON.

KEY

SWITCH:

POWER

ONLY INSTRUMENT CLUSTER.

ENERGIZES

FUEL

LIFT

THE

ENGINE'S

PUMP,

AND

THIS

THE

PUMp,

PROVIDES TO

THE

PANEL

THE THE ENGINE'S

OIL

PRES-

BUTTON

FUEL

ENER-

·6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use fuel that meets the requirements 2-D

Care

Use only clean diesel fuel! The clearance in your fuel injection pump is very critical; invisible dirt particles which might pass through the filter can damage these finely finished parts. keep it clean. The best fuel can careless handling that the fuel going into the tank for your engine's daily use is clean and pure, the following practice is advisable:

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

filters.

ENGINE

Use a heavy duty engine oil with an API classification or CG-4 hours thereafter. For recommended oil viscosity, see the following chart:

A

FUEL

(ASTM), and has a cetane rating

Of

The

Fuel

Supply

It

is important to buy clean fuel, and

be

or

improper storage facilities.

of

Raycor 500

FG

or 900

FG

are good examples

OIL

or

better. Change the engine oil after an initial 50

of

break-in operation, and every 100 hours

Operating

41° -68°F

CAUTION:

engine additives to

produce

Above

68°F

Below

41°F

oil

to

mix.

of

different

properties

Temperature

(20°C)

(5 -20°C)

(5°C)

Do

not

allow

Each

brand

brands

harmful

SAE SAE

SAE

two

contains

could

or

specification

of#45

or better.

of

the components

rendered unsatisfactory by

fuel.

Oil

Viscosity

30,

10W-30

20,

10W-30

to

10W-30

or

your

more

its

react

engine.

or

brands

own

in

of

To

assure

of

operation

or

15W-40

or

15W-40

of

additives;

the

mixture

such

of

Class

CF

ENGINE

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

The antifreeze perfonns 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 anced, crucial to long tenn protection.

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

NOTE:

antifreeze that is now available.

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

A coolant recovery tank kit is supplied with each WESTERBEKE diesel engine. The purpose

tank is to allow for engine coolant expansion and contraction during engine operation, without the loss without introducing air into the cooling system. This kit is provided and must be installed before operating the engine.

NOTE:

located at or above can

particular installation makes this

COOLANT

of

50% antifreeze

50% distilled water. Distilled water is free from the

(SCAs) that keep the antifreeze chemically bal-

be

premixed before

Look for

Temperature

This

be

located below

the

new environmentally-friendly

ANTIFREEZE

Concentration

RECOVERY

tank,

with

its

the

of

PROTECTION

23% 14°F

(-10°C)

TANK

short

run

level

of

the

level

of

long

the circulating pump seal.

30%

8°F

(-13°C)

of

engine's

the

necessary.

35%

-4°F

(-20°C)

of

coolant and

plastic

hose,

manifold,

engine's manifold

50%

-40°F

(-40°C)

this recovery

is best

lasting

but it

if

the

OIL

PRESSURE

The engine's oil pressure, during operation, is indicated

by the oil pressure gauge on the instrument panel. During nonnal operation, the oil pressure will range between 35 and 55 psi (2.5 and 3.9 kglcm

NOTE:

A newly started, cold engine reading an readings engine,

up

to

oil pressure

will.

the

load placed on

60

psi (4.2 kglcm

reading

vary depending

TRANSMISSION

Refer to the TRANSMISSION SECTION type

of

fluid and quantity for each transmission model.

2

).

as

low

FLUID

can

2

).

A warmed engine

as 25 psi (1.8 kglcm

upon

the

engine,

have

an

oil pressure

temperature

and

the

RPM's.

of

this manual for

can

have

2

).

These

of

the

Engines & Generators

7

PREPARATIONS

PREST

ART

INSPECTION

Before starting your engine for the first time longed layoff, check the following items:

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

at the high mark on the dipstick.

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

examine the fuel filter/water separator bowl for contaminants.

D Check the transmission fluid level.

NOTE:

Refer to the previous page

transmission fluid.

for

or

after a pro-

fue~

oil

and

FOR

INITIAL

PLASTIC

START-UP

RECOVERY

TANK

CAP

D Check the

and battery cable connections. Make certain the positive

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

the negative

stud (this location is tagged).

DC

electrical system. Inspect wire connections .

(-)

cable is connected to the engine ground

D Check the coolant level in both the plastic recovery tank

and at the manifold.

NOTE:

If

the engine

refer to the

COOLING SYSTEM section

has

not

yet

been filled with coolant,

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 is proper ventilation around the

engine. An ample supply is necessary for proper engine performance.

D Make sure the mounting installation is secure. D Ensure the propeller shaft is securely attached to the

transmission.

D Open the through-hull and prime the raw water intake

strainer. Inspect the raw water supply.

:.'\Il>'~~

OIL

FILL

CAP

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

THE

STARTING

The

44N35Cdiesel

The start circuitry must be depressed for the time specified in the preheat chart. Then, while keeping the PREHEAT button engaged, the START button

Starting

1.

Place the transmission in neutral and advance the throttle control to slightly open.

A

CAUTION:

in

neutral. damage vessels

2. Tum the KEY SWITCH to the

3. Depress the PREHEAT switch. The voltrrieter, lights, gauges, meters and fuel solenoid will be activated. The PREHEAT switch should be depressed in accordance with the following chart:

SYSTEM

engine has a 12V DC electric starter.

is

designed so that the PREHEAT button

is

depressed to crank the engine.

Procedure

Make

certain

Starting

to

your

nearby.

in

gear

transmission,

the

transmission

could

result

your

boat,

ON

position (2 o'clock).

in

serious

and

is

panel

TemperatureJPreheat

Atmospheric

41°F(5°C)

23°F(-5°C)

Limit

NOTE:

The START button will not energize unless the PRE-

HEAT button

activates the glow plugs in the cylinder head so use the

HEAT intermittently to avoid overheating the glow plugs.

4. While still depressing the PREHEAT button, depress the START button. This will engage the starter solenoid. Upon engine starting, release the START switch. Do not release the PREHEAT switch until the oil pressure reaches 5 - 10 psi. Then as long as the high water temperature and low oil pressure protective circuits do not activate, the engine will remain energized and continue to run.

Temperature

or

higher

to

23°F

(-5°C)

or

lower

of

continuous

is

use

depressed. Depressing the PREHEAT button

Preheating Approx. Approx. Approx.

30

seconds

10

seconds

15

seconds

20

seconds

before

Time

cranking

PRE-

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

30 seconds; repeat the procedure above and preheat

wait longer. Never

A

CAUTION:

the

engine system the cooling enter

filling

pump

system

the 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

NOTE:

engine. Depressing the second intervals will help stabilize the engine rpm until the engine operating temperature reaches (77 - 88°C) and a propeller load is applied

When the engine depressed, a charging load on the discernible.

Starting

Make sure the lubricating oil temperature. SAE

30, lOW-30, or 15W-40. The battery should be fully charged to minimize voltage drop. Use a sufficient amount

Temperature/Preheat chart elsewhere in this section.

run

the starter

Prolonged

starting

is

pumping

engine's

once

the

with

raw

during

cylinders

the

exhaust

by

shutoff,

cause

can

raw

cranking.

closing

draining of

resulting

issue;

the

owner/operator

Never attempt to engage the starter while the

is

running.

Some unstable running may occur

is running and the PREHEAT button

Under

Cold

Conditions

Use oil with an API Specification

of

for

more than 30 seconds.

cranking

result

water.

water

by system the

the

excessive

from

in

the

This

may

through

This

way

fills.

raw

the

exhaust

raw

water

intervals engine

happen

the

raw

of

the

Prevent

water

supply

engine

entry

exhaust

raw

water

exhaust

muffler,

should

in

a cold

PREHEAT button

is

appropriate for the prevailing

preheat to aid in starting. See the

for

170

to

DC

alternator will be

of

is

without

because

water

can

this

and

cranking.

is

not

a

keep

this

10-

15

-190°F the engine.

CF

or CG-4,

is

NOTE:

When starting: A voltage drop will occur when the preheat button is

depressed.

Stopping

To

stop the engine, bring the throttle to place the transmission in neutral. Allow the engine to idle for a few moments to stabilize temperatures. Turn the engine off using the stop control cable. an

optional fuel shut off solenoid, turn off the key switch at

the control panel.

NOTE:

Make certain this key switch is ( 12 o'clock). discharge. operator of key from the key switch after stopping the engine.

Engines & Generators

of

preventing the battery from discharging

9

Procedure

an

idle position and

If

your engine

If

the key switch

An

engine alarm buzzer

this condition (key switch ON). The best method

is

left

is

equipped with

in

the OFF position

ON,

the battery will

provided to warn the

is

to remove the

WARNING

ALTERNATOR

The Captain Control Panel indicates alternator low discharge with a red warning light.

The Admiral Control performance

WARNINGS

Panel uses a voltmeter to monitor the

of

the alternator.

'

LIGHTS,

ALARMS & CIRCUIT

BREAKER

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. Should the engine's oil pressure fall to (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.

ALARM

SWITCH

5 - 10 psi

COOLANT

A coolant temperature switch is located on the thermostat housing. This switch will activate a continuous alarm coolant's operating temperature reaches approximately (99°C). .

COOLANT TEMPERATURE SWITCH

TEMPERATURE

SWITCH

SENDORS

The coolant temperature and oil pressure sendors are not

installed in the Both sendors are, however, included in the Admiral Instrument

These sendors (with connecting gauges) can be added as accessories to either engine at any time and are easily installed to the prewired engine.

44N35C engines as standard equipment.

Panel Kit.

if

the

2100P

DlL

PRESSURE

/

ENGINE

The

DC mounted manual reset circuit breaker Excessive current draw or electrical overload anywhere in the instrument panel wiring breaker to trip. In this event most engines will shut down 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.

SWITCH

SENDOR

CIRCUIT

harness on the engine is protected by an engine-

BREAKER

or

engine wiring will cause the

(20 amps DC).

of

the problem.

If

Engines &

10

Generators

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 is dependent upon how the engine is operated

50

hours

of

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 order

to maximize the performance and service life Perform this conditioning carefully, keeping in mind the fol-

lowing:

1.

Start the engine according to the

use.

50

STARTING

DURE section. Run the engine at fast idle while checking

that all systems (raw water pump, oil pressure, battery charging) are functioning.

2. Allow the engine to warm up (preferably by running at

fast idle) until the water temperature gauge moves into the

130 - 1400P (55 - 60°C) range.

hours

of

the engine.

PROCE-

of

one

of

initial

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

S.

Use caution not to overload the engine. The presence grey or black exhaust and the inability reach its full rated speed are signs

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

of

cold engine.

of

the engine to

an overload.

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:

When the engine is cold - white smoke. When the engine is warm - almost smokeless. When the engine is overloaded - some black smoke and soot.

NOTE:

See

the

TRANSMISSION section

break-in information

on

your transmission.

of

this manual for

a

Engines & Generators

11

THE

DAILY

OPERATION

CHECK

Follow this check list each day before starting your engine.

LIST

D Record the hounneter reading in your log (engine hours

relate to the maintenance schedule.)

D Visually inspect the engine for fuel, oil, or water leaks. D Check the oil level (dipstick). D Check the coolant level in the coolant recovery tank.

Periodically check the manifold coolant level.

D Check the transmission fluid level. D Check your diesel fuel supply. D Look for clean fuel in the fuel filter/water separator trans-

parent bowl.

D Check for loose wires at the alternator and make sure its

mounting is secure.

D Check the starting batteries (weekly). D Check drive belts for wear and proper tension (weekly). D Check the raw water pump to make sure its mounting is

secure.

STARTING

NOTE:

manual for

1. Put the transmission in neutral, throttle advanced.

NOTE:

neutral safety switch through which energizing circuit passes. transmission energize.

2.

Tum

3. Depress PREHEAT

4. While pressing PREHEAT, push fires, release

S.

Hold PREHEAT until the oil pressure reaches and/or the alarm shuts off.

NOTE:

engine. temperature

NOTE:

then

6. Allow a few minutes for the engine to warm at a comfortable rpm (approximately rpm, and get underway.

THE

ENGINE

See

STARTING/STOPPING PROCEDURE

more

detailed instructions.

Hydraulically operated transmissions have a

the

starter solenoid

This

switch

is

open

is

in

gear

so

the

starter solenoid will not

the KEY to the

START.

Some

unstable running may occur

This

condition should abate as normal operating is

Should

repeat

the

ON

position (2 o'clock).

(10 to

15

reached and loads

the

engine

fail

to

above

procedure,

1000 rpm), then reduce the

seconds).

START. As the engine

in

are

applied.

start,

wait

and PREHEAT

when

a cold

30

seconds,

in

15

this

the

psi

longer.

Engines & Generators

12

MAINTENANCE

In order to use this Maintenance Schedule, it will be necessary to log your engine hours. record your engine hours by running time.

NOTE:

Many

of

the following maintenance procedures are simple but others are more difficult expert knowledge

of

a service mechanic.

Use your engine hourrneter or

and

may require the

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

any

and

battery

service

safety

use

the

DC

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Transmission

Drive

Visual

Fuel Starting

(and

Engine

Heat

Fuel/Water Exhaust

Engine

Throttle Control

Adjust Raw

Separator

Oil

level

Fluid

Belts

Inspection

Filter

Batteries

House

Batteries)

Oil

and

Exchanger

Separator

System

Hoses

and

Transmission

Cable

Engine

Water

Pump

of

Filter

Zinc

Idle

level

Engine

Anode

Speed

CHECK

EACH

DAY

0

0 0 0 0 0

weekly

0

weekly

HOURS

OF

OPERATION

50

100

250

500

750

1000

1250

NOTE:

Keep

engine

surface

clean.

Dirt

oil

will

cool.

0

inhibit

the

engine's

ability

0 0 0 0 0

to

remain

and

0 0 0 0 0 0 0 0 0 0

0 0

0

0 0 0 0 0 0

0 0

0 0 0 0 0 0

0 0

0

0 0 0

0

Diesel

No.2

Check

for

if

necessary).

Oil

level

should

dipstick. Check

at

recovery

Add

coolant

Fluid

level

on

dipstick.

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Change

at

Check

electrolyte

and

make

excessive Initial

engine

change

both

Inspect

zinc

exchanger Change

filter

Initial

check

Inspect

for

tion.

Check corrosion replace

as

tig

ht.

Check

Hose

should

spongy.

Check

for

Lubricate

Adjust

Remove gasket, and

Lubricate

to

the

cam

seals

with 750 -1000

when

MAINTENANCE

rating

water

and

indicate

if

needed.

should

indicate

proper

if

needed.

fuel,

oil

and

connections.

loose

belt

50

hours

levels

sure

connections

corrosion.

oil & filter

every

anode,

end

of

zinc

every

at

50

hours,

leaks.

Check

the

exhaust

buildup

necessary.

casti

ng

be

hard & tight.

and

loose

fittings,

WD-40

pump and

cover

(the

shaft

reassembling.

of

45

dirt

between

tank;

if

tension

Check

water

tension. then

every

change

100

hours.

replace

anode

200

hours.

anti-siphon

elbow

on

inside

Check

integ

tighten

cotter

or

rpm

cover

for

can

turn,

cetane

in

every

then

rity.

equivalent.

and

DESCRIPTION

empty,

between

(3/8"

all

wear.

or

higher.

fuel

(drain/replace

MAX.

check

MAX

to

1/2"

belt

edges

leaks.

Inspect

Keep

bolts & nuts

250

hours.

50

operating

are

very

at

50

if

needed.

debris.

every

250

valve

for

carbon

passages;

that

all

connections

Replace

hose

clamps.

pins,

etc.

inspect

Check

but

not

and

LOW

at

manifold.

and

deflection)

for

wear.

wiring

hours

tight.

Clean

hours,

then

Clear

the

hours.

opera-

and/or

clean

and

if

soft

or

the

impeller,

the

bearings

wobble).

( continued)

filter

on

LOW

tight.

off

heat

are

--+

Engines & Generators

13

NOTE:

Use

engine

the

hours by

MAINTENANCE

engine

hourmeter

running

time.

gauge

to

log

SCHEDULE

your

engine

hours

or

record

your

SCHEDULED

MAINTENANCE

Coolant

System

DC

Alternator

Air

Intake

Filter

Transmission

Engine

Transmission

Damper *Fuellnjectors

*Starter

*Preheat

Lubricate with

Transmission

Plate

Motor

Circuit

*Engine

*

*Heat

Fluid

Cylinder

Compression Adjust

the

Valve

Exchanger

Panel

"Lockeze"

Oil

Cooler

Clearances

Key

Switch

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

D D

D D D D D D

D

D D

D

D D

D D D D D D

D D D

D

1000

D D

D

D D

1250

Drain. priate

Check

D

bracket; Clean

Remove;

tested. Chattering

of

damper

Check spray

Check and pinion

Check

clean

compound Check

Adjustments).

Adjust

ADJUSTMENTS).

Remove.

tested. At

Initial 300

MAINTENANCE

flush.

and

antifreeze

DC

charge

tighten

every

100

have

at plate

and

adjust

condition

solenoid

lubricate.

drive. operation

glow

plugs. on

compression

Valve

Clearances

have

first

100

hours.

fluid

change

hours

or

refill

cooling

mix.

from

alternator.

electrical

operating

professionally

idle

wear.

(see

and

Clean

of

threads.

professionally

at

winterizing.

and

low

Remove

injection

ENGINE

motor and

lubricate

preheat

Reinstall

pressure

(see

then

each

at

25

connections.

rpms

hours.

DESCRIPTION

system

with

appro-

Check

mounting

hours.

cleaned

and

pressure

is

an

indication

and

replace.

opening

for

pressure

ADJUSTMENTS).

corrosion.

solenoid.

with

anti-seize

and

timing

ENGINE

cleaned

year

then

Remove

the

starter

Remove

(see

and

pressure

at

winterizing.

every

and

motor

and

Engine

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

14

mechanic.

COOLING

SYSTEM

DESCRIPTION

Westerbeke marine diesel engines are designed and equipped

for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolant cools the engine block, its internal moving parts, and the engine oil. The heat is transferred externally

from the fresh water coolant to raw water by means

exchanger, similar in function to an automotive radiator. Raw water flows through the tubes fresh water coolant flows around the tubes; engine heat trans-

ferred to the fresh water coolant is conducted through the

tube walls to the raw water which is then pumped into the

exhaust system where finally it is discharged overboard. In

other words, the engine is cooled by fresh water coolant, this coolant is cooled by raw water, and the raw water carries the transferred heat overboard through the exhaust system. The fresh water coolant and raw water circuits are independent 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:

WATER

Refer

to

COOLING

the

ENGINE COOlANT section for

ommended antifreeze and water mixture

fresh water

Fresh water coolant is pumped through the engine by a circulating pump, absorbing heat from the engine. The coolant then passes through the thermostat into the manifold, to the heat exchanger where it is cooled, and returned to the enaine

block via the suction side

coolant.

of

the heat exchanger while

CIRCUIT

to

be

of

the circulating pump. 0

the

used as

of

a heat

of

rec-

the

When the engine is started cold, external coolant flow is prevented by the closed thermostat (although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating). As thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion cooling system.

Coolant

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

CHANGING

The engine's coolant must be changed according to the

Recovery

of

coolant and without introducing air into the cool-

Tank

COOLANT

MAINTENANCE SCHEDULE.

become contaminated, it can lead to overheating problems.

A

CAUTION:

Proper critical; a substantial traced

back

to

cooling

To drain

pressure cap and unfasten the drain hose as shown below.

NOTE:

be

out

The

drain petcock

used

to

help

A

WARNING:

Wear

protective

the old engine coolant, loosen the manifold

drain

engine

Beware

gloves.

the engine warms up, the

If

the coolant is allowed to

cooling

number

system

on

system

of

maintenance

engine

corrosion.

the

heat exchanger should also

coolant.

of

the

hot

engine

of

the engine's

or

above the

failures

coolant.

of

can

the

is

be

ENGINE

BLOCK

RELEASE FROM DRAIN THE

THE

OIL

THE

COOLANT

ENGINE

COOLANT

BLOCK

COOLER

FROM

LINE

TO

Engines &

15

OIL

Generators

FILTER

COOLING

SYSTEM

Refilling

After replacing exchanger's coolant petcock. Then pour clean, premixed coolant the

NOTE:

When

the

Monitor the

sure cap.

Remove coolant the

flow After checking for leaks, stop the engine and allow it

Coolant should draw back into 'the cooling system engine needed.

RECOVERY

FROM

RECOVERY

NOTE:

pressure

good the closes cap. coolant passage

coolant within able to

and

the

Coolant

the

engine block drain

into

the

manifold

manifold, start

Open

the

air-bleed petcock

a steady flow

petcock and fill

the

coolant

manifold

cap.

into

TO

to

the filler neck

the

cap on the coolant recovery tank

mix

to

halfway between LOW and MAX

Run

the engine

the

recovery tank.

coolll

down.

Cle~

up

COOLANT

TANK

COOLANT

TANK

Periodically check

cap.

Ensure

condition.

Check

any

and

the

engine

of

coolant appears at

the

system until

in

the

and

Add coolant

spilled coolant:

the

upper and lower rubber seals

to

ensure

vacuum valve opens and

tightly.

Carry a spare

Check

also

to

ensure

is

clear

so

the

system

is

to

expand and contract

from

the

coolant

recovery

plug,

close

when

the coolant

and

run

on

the

manifold

and

install the manifold pres-

observe

to

the recovery tank if

KEEP

THE

COOLANT

CLEAR

COOL4NT

it

the

manifold

and

the

PASSAGE

EXPANSION

is

at

slow idle.

heat

exchanger.

the

petcock, close

add

as

needed. Fill

and

coolant expansion

PRESSURE

of

/CAP

the

manifold

~~:;-m;;iiiiII

COOLANTRETR4CnON

condition

the

tank.

the

heat

visable

remains

fill

with

and

replace

to

as

the

THERMOSTAT

A thermostat, located near engine, controls

uously

flows

engine

is

from

flowing thermostat As

~e

engine thermostat replaced

the

through the closed cooling circuit. When

first

started,

(some coolant

to

prevent the exhaust manifold

warms

is

accessible

easily.

Carry a spare thermostat

the

manifold at

coolant temperature

the

closed thermostat prevents coolant

is

by-passed through a hole in

up,

the thermostat gradually

and

can

be

the

front of

as

the

coolant contin-

from

checked, cleaned, or

and

gasket.

the

overheating).

opens.

full.

cool.

are

The

in

the

Replacing

Remove ing

as

ket,

apply before pressirig it into place. screws.

Run

the

there

THERMOSTAT ASSEMBLY

RAW

The

raw

impeller

water source (ocean, lake, or river) through a hose water strainer. The

through the the

heat exchanger tubes) where it cools the engine circulat-

ing

fresh water coolant. The raw water

into

the

ing

the

water

discharge pressure.

Raw

The

raw non-ferrous housing and a neoprene impeller. The impeller has

flexible vanes which wipe against a curved within On

no lubricant for the impeller Raw

water water) is not present during engine operation. Such are not warrantable, raw

water

NOTE:

(seals chase

the

Thermostat

the

cap

screws

and

disassemble

shown. When installing

a thin coat of sealant

engine

and

check for normal temperatures

are

.no

leaks

at

the

WATER

exhaust gasses. This mixture of exhaust

is

Water

the account should

COOLING

water

flow

is

created

pump.

This pump draws water directly

raw

water pump

water-injected exhaust discharged overboard

Pump

water

pump

is

impeller housing, producing

this

imp~ller.

and

impeller cover gasket (an impeller kit)

pump

impeller failures occur

and

flow

is

present at start-up.

the

on

Do

not over-tighten

thermostat housing.

CIRCUIT

by

water passes

to

the

elbow,

by

a self-priming, rotary

pump be

There should always

operators are cautioned

Should a failure occur with

and

bearings), it may

a new pump and rebuild

be

more the

the

new thermostat

both sides of

a positive displacement

from

heat exchanger (through

is

then discharged

mixing with

the engine's exhaust

the

run

dry

when

the

pump:r

cost efficient

original pump

thermostat

au.d

gas-

the

gasket

the

cap

and

that

TEMPERATURE

SENDOR

[OPTIONAL]

from

the

to

the

strainer

and

cool-

gas

and

gas

pump

with

cam

plate

pumping action.

as

water

acts

be

a spare

aboard.

lubricant

failures

to

make sure

internal parts

to

pur-

as a spare.

hous-

raw

(raw

raw

a

as

a

Revised: February 2002

-.¥'

WESTERBEKE

Engines & Generators

16

COOLING

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 bling, apply a thin coating

gasket.

the

Raw

Water

of

two small screwdrivers, carefully pry the

of

the pump. Install the new impeller and gasket.

Open the raw water intake valve.

Pump

Impeller

of

lubricant to the impeller and

~@

1:

assem-

NOTE:

Also follow

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 flow raw water through the cooling system.

STRAINER FILTER

the

above procedure after having

I

L~.--.

f ,

~--~

TYPICAL

RAW

Owner

WATER

Installed

INTAKE

STRAINER

run

hard

of

A

CAUTION:

impeller, cooling

circuit.

they

If

must

They

any

be

often

of

the

found

can

vanes to

prevent

be

have

found

broken

blockage

in

the

heat

off

in

the

exchanger.

Raw

Water

NOTE:

the

strainer will always

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

5. Reassemble and install the strainer. Open the seacock.

6.

7. Run the engine and check for leaks.

Intake

Always install

Strainer

the

strainer at or below

be

self-priming.

if

necessary.

the

waterline

100 hours

of

this

the

of

so

HEAT

EXCHANGER

The heat exchanger is a copper cylinder which encloses a number

the small copper tubes and the fresh water coolant from the engine is circulated around the copper tubes. The raw water removes heat from the fresh water coolant.

of

small copper tubes. Raw water is pumped through

HEAT

EXCHANGER

PETCOCK

HEAT GASKET

CLEAN

DEBRIS

ZINC ANODE

EXCHANGER

Engines & Generators

17

COOLING

Zinc

Anode

~

zi~c

~o~e,

or

pencil, is located in the raw water cooling

CIrCUIt

wIthin the heat exchanger.

zinc

~odes

is to sacrifice them to electrolysis action taking

place

In

the raw water cooling circuit, thereby reducing the

of

effects The and the anode cleaned or replaced as required. Spare anodes should

NOTE:

electrolysis on other components

condition

NEW

Electrolysis action

be

of

the zinc anode should

carned

on

board.

REPLACE

is

installation and vessel location; not that

the

The

purpose

resultof

of

having

of

the system.

be

checked monthly

CLEAN & REUSE

each

particular

of

the

engine.

SYSTEM

If

the zinc anodes need replacement, hold the hex boss into

which the zinc anode is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing removing the zinc, note the condition poor condition, there are probably a lot the exchanger. Remove the end clean the inside exchanger end gasket in case the present one becomes aged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number), O-ring and cover, and install a new zinc anode.

NOTE:

The

do

not

require insulate ing

Heat

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

NOTE:

the

preventing electrolysis action

Exchanger

Operating

of

threads

sealant.

zinc from

all zinc debris. Always have a spare heat

of

in that a heat exchanger cleaning every

1000

hours.

off

the exchanger shell. After

of

the heat exchanger and

the

zinc anodes

are

Sealant should not

the

metal

of

the

heat exchanger

on

the

Service

of

operation, remove, clean

silty and/or tropical

be

performed

it.

If

the zinc is in

of

zinc flakes within

pipe

threads

be

used

as

zinc.

waters

may

require

more

often

dam-

and

it

may

hous-

than

AIR

INTAKE I SILENCER

Description

A marine diesel engine running at high speed will typically consume more than must the engine room be well ventilated, the air flow into the

engine must be unrestricted.

Air

Filter

The air filter cartridge prevents engine room dust and dirt from entering the engine,

6,000 cubic feet

of

air

per

hour. Not only

Maintenance

The filter should

the cartridge on a flat surface to dislodge loose dirt off with compressed air. or oily, replace it.

be

cleaned every 100 operating hours. Tap

or

If

the cartridge is badly contaminated

clean .

"'~~~~----FILTER

CARTRIDGE

Engines & Generators

18

DIESEL

Use not

FUEL

A primary installed between the fuel tank and water be

Most installers include a

installation package contaminants

A typical is separator tank will ment. the impurities. maintaining a proper

FUEL

No.2 diesel

use

kerosene or home heating

fuel

FILTER/WATER

fuel

filter of the water separating type must be

and

other contaminants from the

carried

to

the

fuel

as

in

the

fuel

filter/water separator

the

Raycor Model 500 MA.

type

filter

is

and

engine-mounted

affect

the

fuel pump, engine

The owner/operator

fuel

reaching

This

the

engine's injection equipment

process

with a cetane rating of 45 or

SEPARATOR

system

on

the engine.

fuel

filter/water separator with

they are aware of

can cause.

Keep

not installed between

fuel

system,

is

responsible for making certain

is

accomplished

fuel

filter/water

fuel.

the

engine

fuel

before they

the

problems that

is

illustrated

in

mind that if a water

the

any

water in the

filter,

and injection equip-

by

installing

separator.

to

remove

below.

fuel

higher.

is

FUEL

supply

free

and

SYSTEM

Do

can

the

This

fuel

of

FUEL

FILTERS

The

fuel

injection pump and the fuel injectors manufactured and they must receive clean diesel from

water

and

dirt.

To

ensure this must pass through at least separator clean, schedule

A

when

any

open tem when

and

the engine's spin-on fuel

and

change these filters according

in

this

manual.

WARNING:

servicing

fuel

that

flames

when

servicing

Shut

the

mlY

spill.

or

other

servicing.

the

fuel

sources

Ensure

fuel

two

off

system.

DO

system.

fuel

the

NOT

proper

flow

filters, a

fuel

Take

allow

of

fire

valve

ventilation

are

of clean

fuel

filter.

Visually inspect,

to

the

at

the

care

in

any

smoking,

near

the

precisely

fuel,

free

fuel,

the

fuel

filter/water

maintenance

tank

catching fuel

sys-

exists

FUEL

FILTER

WATER

FUEL

The the fuel owner-operator requires servicing, remove it and take it injection ble

The the speed (see

ADJUSTMENTS).

FUEL

Periodically check pump fittings one of

tions. When energized thru the preheat circuit,

SEPERATOR

~

I~~~ION

fuel

injection pump

diesel engine, requiring

injection pump has been thoroughly bench-tested and the

pump

and

repair

only

adjustment

fuel

injection pump

IDLE SPEED

LIFT

and make sure that

are tight and secure. The

the

pump's mounting bolts should

secured

will flow

by

the

purge air

of

fuel

as

PUMP

is

cautioned not

service

it.

PUMP

the

mounting bolt

from

the fuel system

the

engine

~

~'

~

.:~:~

is a very

facility.

the

servicing mechanic should make

is

the adjustment for engine idle

ADJUSTMENT

fuel

no

is

important component of

the

utmost care in handling. The

to

attempt

Do

not attempt

connections

leakage

DC

to

ensure proper pump

running.

to

service

to

an

authorized

to

under ENGINE

to

and

out of

is

present

ground connection at

and

provide a continuous

be

the

and

clean

fuel

it.

disassem-

the

that

and

well

opera-

lift

pump

If

fuel

the

it

to

ENGINE,

Periodically check the leakage. Clean the filter element with kerosene or diesel after the first 50 hours then follow the MAINTENANCE

SCHEDULE

Changing/cleaning

1.

Shut off

2.

Unscrew housing housing,

3.

Remove

4.

Replace the sealing

the

housing. Thread the retainer ring

to

cross thread. When retainer contacts tighten run

the

FUEL

FILTER

fuel

connections and

for cleaning and replacement.

the

filter

the

fuel

supply.

the

retainer ring that holds the

and

allow

and

replace

114 -1/2 engine

the bowl

"0"

turns

to

inspect for leaks.

to

the

filter element

ring

and

by

hand.

the

element

filter

come

away

and

reassemble the

on

carefully

the

Open

the

from

clean

"0"

fuel

I

bowl

supply

BOWL

for

the

bowl

so

ring,

fuel

to

bowl.

as

and

FUEL

FILTER

I

the

to

not

Engines & Generators

19

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid. When PREHEAT is pressed at the control panel this solenoid should

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

INSPECTION

To inspect the plug, remove the electrical terminal 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 bum erosion;

if

it has eroded too much, replace the plug.

TESTING

An accurate way to test glow plugs is with an ohmmeter. Touch one prod to the glow plug's wire connection, and the other

t~

the body

plug

wIll have a 0.4 - 0.6

used with the plug in

an ammeter to test the power drain

A

WARNING:

to

the

touch.

testing

the

of

the glow plug, as shown. A good glow

ohm

resistance. This method can be

or

out

of

the engine. You can also use

(5

- 6 amps per plug).

These

glow

plugs

will

become

Be

careful

not

to

burn

your

plugs.

fingers

very

when

hot

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to seconds. circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

A

than

Glow

If

the plugs

WARNING:

30

seconds.

Plug

Tightening

Torque 7 -11

don't

heat up quickly, check for a short

Do

not

keep a glow

H-Ib

TESTING A GLOW

WITH

AN

OHMMETER

plug

(1.0

PLUG

-1.5

on

for

m-kg)

15

more

TERMINAL

,END

TIP

TESTING A GLOW USING A TEST

LIGHT

PLUG

+

'~IWESTERBEKE

I Enaines & Generators

20

ENGINE

LUBRICATING

OIL

SWITCH

ENG'INE

1.

BMM

11/16

INCH

SOCKET

LUBRICATION

OIL

PRESSURE

OIL

DIAGRAM

PRESSURE

-_:lHI

OIL

CHANGE

Draining the Oil Sump. Discharge the used oil through

the sump drain hose (attached to the front while the engine is warm. Drain the used oil completely, replace the hose in its bracket, and replace the end cap securely.

NOTE:

Thread

size for

is

114NPT.

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

water present in the oil can

exhaust system attached to the engine and/or a siphoning

of

raw water through the raw water cooling circuit into the exhaust, filling the engine. This problem is often caused by the absence location or lack

the

lube

oil drain hose capped end

~Oll

of

maintenance.

ORAl.

it

is removed. A

be

the result

an anti-siphon valve, its poor

of

the engine)

HOSE

of

it

does require

of

a fault in the

water in

2.

Replacing the

ter, you may find it helpful and cleaner to punch a hole in the upper and lower portion oil from it into a container before removing it. This helps to lessen spillage. A small automotive filter wrench should be helpful in removing the old oil filter.

NOTE:

Do

filter

to

Place some paper towels and a plastic bag around the filter when unscrewing it to catch any oil left in the filter. (Oil or any other fluid cooling ability. Keep your engine clean.) Inspect the old oil filter as sealing gasket comes off with the old oil filter. ber sealing gasket remains sealed against the filter bracket, gently remove it.

SEALING

APPLY

CLEAN

WHEN

INSTALLING

When installing the new oil filter element, wipe the filter gasket's sealing surface on the bracket free apply a thin coat on the new oil filter. filter nipple on the oil filter bracket, and then tighten the filter firmly by hand.

NOTE:

Generic filters

ial

standards or diameters parts might Immediately after

engine there

are

3.

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

cap on the top After refilling, run the engine for a few moments while checking the oil pressure. Make sure there is no leakage around the new oil filter or from the oil drain system, and stop the engine. Then check the quantity lube oil dipstick. Fill to, the dipstick, should the engine require additional oil.

Oil

Filter.

When removing the used oil fil-

of

the old filter to drain the

not punch this hole without first

make certain it

it

is removed to make sure that the rubber

GASKET

ENGINE

be

entirely different from genuine

to

make

no

oil leaks around the new oil

of

can

be

removed.

on

the engine reduces the engine's

/

OIL

SPIN

ON

TURN

ON

HAND

TIGHT

of

clean engine oil to the rubber gasket

Screw the filter onto the threaded oil

are

not

recommended.

of

important items

an

oil filter change and oil

sure

the

oil pressure

the engine

but

or

not over the high mark on

is

normal and that

through the side oil fill.

loosening

If

of

oil and

as

the on parts.

fill.

filter.

of

oil with the

the

this rub-

mater-

generic

run

the

Engines & Generators

21

OIL

PRESSURE

The engine's oil pressure, during operation, is indicated by the oil pressure gauge normal operation, the oil pressure will range between 60 psi (2.8 and 4.2 kglcm

NOTE:

reading an readings engine

OIL

PRESSURE

A newly

oil pressure

and

up

to

60

will

vary

the

SWITCH"

started,

psi (4.2 kglcnf). A warmed engine

reading rpms.

on

2

).

cold engine

as

low

depending

/

the instrument panel. During

can

have

an

as 35 psi (2.5 kglcm

upon

the

temperature

OIL

oil pressure

can

2

).

of

OIL

LINE

PRESSURE

TESTING

The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by

40

and

have

These

the

the oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points in the engine. The oil then returns to the oil sump to repeat the continuous cycle. When the oil pressure exceeds the fied pressure, the oil pushes open the relief valve in the oil pump and returns to the oil sump, keeping the oil pressure within its specified range.

To

test the oil pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place. After warming up the engine, set the engine speed at and read the oil pressure gauge.

Oil

Pressure

Sender

LOW

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3

+ 0.1 kglcm

a worn bearings. For additional information on low oil sure readings, see the ENGINE

OIL

PRESSURE

35.0

Ib/ill'

and

Switch

Torgue

OIL

PRESSURE

2

).

A gradual loss

(3.8

kg/em')

or

more

at

3000

9 -13

ft-Ib

(1.2

-1.8 m -

of

oil pressure usually indicates

TROUBLESHOOTING

speci-

3000 rpm

rpm.

kg).

pres-

chart.

OIL

PRESSURE

An oil pressure relief valve is located just

below the injection pump. This valve opens at

appoximately

LOCATED UNDER FUEL

INJECTION

PUMP

ON

ENGINE

RELIEF

50

psi [343 kpa] and maintains that pressure.

JUST

THE

BLOCK.

VALVE

on

OIL

PRESSURE

AS

AN

WITH

GAUGE.

WITH

THE

INSTRUMENT

the engine block

SENDOR

ACCESSORY

..

STANDARD

ADMIRAL

PANEL.

.

TESTING

OIL

PRESSURE

+

t-

OIL

PRESSURE

I~IWESTERBEKE

, Enaines & Generators

22

REMOTE

OIL

INSTALLATION

This popular accessory is used to relocate the engine's oil fil-

ter from the engine to a more convenient location such as an

engine room bulkhead.

NOTE:

Refer to ENGINE OIL CHANGE

instructions on removing the oil filter.

APPLY A THIN INSTALLING TIGHTEN CONTACTS

COAT

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

OF

CLEAN

THREAD

3/4

OIL THE

TURN

TO

THE

KIT

ON,

AFTER

O-RING

THEN

THE

NOTE ON REMOVED

,

WILL

in

WHEN

HAND

O-RING

THE

"IN"

THE

ADAPTER

FOR

BE

RECONNECTED

this

manualfor

AND

"OUT"

MARKINGS

WHEN

THE

INSTALLATION

HOSES

SO

CORRECTLY.

ARE

THEY

FILTER

{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:

incorrect installation

Westerbeke is

not

responsible

of

the Remote Oil Filter.

for

FASTEN

(SCREWS

engine failure due to

SECURELY

TO A BULKHEAD

ARE

OWNER

SUPPLIED)

A

CAUTION:

rectly.

If

the

pass

valve

from

reaching

failure.

immediately

If

oil

in

the

there

and

It

is

flows

filter

engine

is

no

check

vital

to

install

in

the

reverse

assembly

causing

oil

pressure

the

hose

the

will

an

reading~

connections.

oil

lines

cor-

direction~

prevent

Intemal

the

by-

the

oil

engine

shutdown

Engines & Generators

23

APPLY A THIN·

TER

GASKET

FILTER

CDNTACTS

ADDITIONAL

COAT

WHEN

3/4

TURN.

DF

CLEAN

INSTALLING.

THE

BASE,

OIL

TO

THE

AFTER

TIGHTEN

THE

IT

FIL-

AN

WATER

HEATER

WATER

This engine is equipped with connections for the plumbing engine coolant to transfer heat to an on-board water heater. The water heater should either in a high or low position in relation to the engine, so that the connecting hoses from run in a reasonably direct line without any loops which might

trap air.

THESE

HOSES CONNECTED IS

NO

WATER

HEATER

-==~~~"

ARE

IF

THERE

HEATER.

INSTALLATIONS

be

mounted in a convenient location

the heater to the engine can

\~

I

.J

,

I

WATER BELOW

HEATER ENGINE

of

The pressure cap on the engine's manifold should installed coolant. Finish filling the cooling system from the remote tank after the system is filled and is free good coolant circulation. During engine operation, checking the engine's coolant should not at the engine manifold cap. heater to the remote expansion tank should supported so it rises continuously from the heater to the tank, enabling any air in the system to rise up to the tank and out of

aft~r

the system.

the engine's cooling system is filled with

of

be

done at the remote tank and

The

hose connection from the

be

air and exhibits

be

routed and

Hoses should rise continuously from their low point heater to the engine so that air will rise naturally from the heater to the engine. then an air bleed petcock must ting on the heater for bleeding air while filling the system.

NOTE:

If

any portion engine's remote circuit tank

own

expansion tank (Kit #024177) must

to

become

into

the connections for single

line

up

engine's

return. nient location remote

expansion tank will

point.

fill

The plastic coolant recovery tank

the remote expansion tank kit

If

trapped air is able to rise to the

of

the

pressure

heater

to

so

cap,

the

highest point.

circuit,

the

return.

the

tank's location and

Install

the

coolant level can easily

be

installed at the higher fit-

heating circuit then

a pressurized

rises

be

Tee

the

remote

choosing

Tee

remote

now

the

higher

at

the

heater,

and plumb a

the

other back

expansion tank

serve as a check and system

is

installed, since this tank

serves the same function. Remove and store

recovery

tank

if

it has been already installed.

at

the

hel:\ter,

above

the

(aluminum)

installed

in

expansion

of

the

two

to

in a conve-

be

checked.

not used when

the

plastic

the

the The

NOTE:

An air bleed petcock

heat

exchanger. coolant system Close

tightly after all

is

located

Open

this petcock when filling

to

allow air

the

air

in

the

is

on

exchanger

removed.

the

engine's

the

engine's

to

escape.

Engines &

24

Generators

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 on the back

#14

GRAY==~=*-

#14

PINK~~~~~~~

#14

BLUE=

ALTERNATOR

A

WARNING:

hot.

Do

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

The alternator charging circuit charges the starting battery and the service battery. An isolator with a diode, a solenoid or a battery selector switch is usually mounted in the circuit 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

of

the use

TROUBLESHOOTING

A failed

not

touch

until

the

Alternator

of

a DC belt driven alternator

DC

wiring harness, a

of

integrated circuits

is

very compact and

of

the alternator.

__

SEE FOR TO

alternator

the

alternator

If

can

has

it.

the alternator is charging the

(Ie's),

is

WIRING

WIRE

OPTIONAL

become

cooled

is

not discharged

the

mounted

DIAGRAM

CONNECTIONS

ALTERNATORS.

very

.

down.

If

it is

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 DC volts.

If

the voltage

a.

is

working; omit Steps 3 through 8 and go directly

tor to "Checking the Service Battery" on the next page.

If

the voltage remains around

b.

exists with either the alternator or the charging circuit; continue with

is

increasing toward

Steps 3 through

14

volts, the alterna-

12

volts, a problem

8.

mID

MULTIMETER

G

COM

TESTING BATTERY/ALTERNATOR (ENGINE

3. Tum off the engine. Inspect all wiring and connections. Ensure that the battery terminals and the engine ground connections are tight and clean.

4.

If

ensure that it

S.

Tum on the ignition switch, but do not start the engine.

6.

Check the battery voltage. tion, the reading should be 12 to

THE

STARTING

RUNNING)

-=

A

CAUTION:

charging switch

when

a battery selector switch

To

avoid

circuit,

never

the

engine

is

on the correct setting.

GROUND

damage

shut

is

If

to

the

off

the

engine

running!

in the charging circuit,

the battery

13

is

volts.

battery

in

good condi-

A

CAUTION:

that

everyone

sheaves

A

DC applications. isolate before made

and

WARNING:

~nd

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

knowledge

the

engine

parts!

together

shut

AC

of

Keep

down

tests

AC

circuits.

make

away

in

power

the

should

certain

from

marine

cord,

engine be

Engines & Generators

25

TESTING

ALTERNATOR

(IGNITION

THE

VOLTAGE·

ON -ENGINE

OFF)

~

0~--MULTIMETER

COM

-=

GROUND

7.

Now

check

minal

(B+)

the

alternator

tor

is

in

the

neither

of

the between connections -look

the

voltage

and

ground.

will

be

circuit

above

alternator

between

If

the

same

the

alternator

is

true, a problem and

the

for

an

opening

the

circuit

as

the

voltage

battery.

DC

alternator

is

good,

battery,

will exists Check

in

the

charging

ELECTRICAL

output

ter-

the

voltage

at

or

if

an

isola-

be

zero.

If

in

the

circuit

all

the

circuit.

SYSTEM

Checking

Check

have

a voltage running. charging circuit. Troubleshoot circuit isolator,

the

voltage of

If

not,

by

checking

battery

the

between

there

switch,

Service

the

service

13

is

a problem

the

wiring

and

Battery

battery.

and

14

volts

in

the

service

and

connections,

the

battery

the

This

when

service

battery

itself.

battery

the

engine

battery

charging

the

should

is

solenoid,

TESTING BATTERY (ENGINE

8.

Start

the

alternator output

The

voltage should is

over-

service

NOTE:

Before

voltmeter

the

EXC terminal if

at

tery

voltage at

If

12

volts

wiring

THE

STARTING

IALTERNATOR

RUNNING)

engine

again.

Check

the

voltage between

and

ground.

reading

be

between

or

under-charging,

facility.

to

ensure

is

and lookfor breaks and poor

for

a properly operating alternator

13.5

and

removing

the

not present at

the

that 12 volts

the

B output

14.5

volts.

have

it repaired

alternator for

DC

previous test showed only

terminal.

the

EXC

....

at

a reliable

trace

ENGINE GROUND

the

use

a bat-

the

-c==-

If

your alternator

repair,

excitation is present

terminal,

connections.

MUlTIMETE".

GROUND

A

CAUTION:

do

not

use a high

performing

G

COM

To

tests

on

avoid

voltage

the

altemator

,SERVICE

TESTING BATTERY

damaging

tester

(i.e. a megger)

charging

THE

the

altemator

BATTERY

SERVICE

(ENGINE

RUNNING)

diodes,

when

circuit.

12

VOLT

DC

The

engine

has a 12

shown

on

the diagrams electrical

A

circuit,

.

the

however,

engine's

when system.

CAUTION:

never

engine

to

electrical circuit.

BATTERY

The

minimum

the

engine's

Cranking

Amps

CONTROL

wiring

troubleshooting or

To

shut

is

running.

avoid

recommended capacity of

12

volt

(CCA).

CIRCUIT

volt

DC

electrical control circuit that

diagrams that

avoid

damage

off

the

engine

Shut

off

electrical

DC

shorts

control circuit

follow.

when

the

servicing

to

the

battery

engine

when

the

is

600 -900

Refer

to

battery

switch

battery

working

battery

is

these

the

DC

charging

while

Switch,

on

the

used

in

Cold

Engines & Generators

26

Battery

Review establish a systematic maintenance schedule engine's starting batteries

o Monitor o Check

o

Care

the

manufacturer's recommendations

and

house batteries.

your

voltmeter

engine operation. '

the

electrolyte

hydrometer. Use

only

distilled water

level. Make

certain that

tight

to

the

battery

Keep

your

batteries

A

WARNING:

caUSII

severe

protective

Sulfuric

burns

gear.

for

level

to

battery

cable connections

posts

(and

clean

and

acid

on

skin

proper

and

bring

to

free

In

and

charging

specific

electrolytes

your

of

lead

damage

engine). corrosion.

batteries

and

then

for

your

during

gravity

with

to a proper

are

can

clothing.

clean

Wear

a

and

MARINE

ENGINE

SEE

NOTE:

An

should

be

circuit

to

disconnect

starter

from

an

emergency

leaving

the

volt

engine

typically

draw

amps

when

switch

with a continuous

rating

of

175

VDC

will

normally

this

function,

must

never

"make"

the

I I

NOTE

'~'

I I

...I

on-off

switch

installed

in

the

battery

and

when

boat.

Twelve

starters

200

to

cranking.

amps

at

serve

but a switch

be

used

to

starter

circuit.

this

the

300

A

12

in

WIRING

DIAGRAM

$I

#39144

=

~

: ::r----------------...I

; ; ;

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GP

•

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l

~~~~~~~~~~~~~~!·'!·1·!L'~~~~~~~~~~~~~~:;~

slIe

Engines & Generators

______

27

-----,l

~

Revised December 2002

MARINE

ENGINE

WIRING

~

12

VDC

~------~~r71------~Mr-------------.

START

SOL.

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SENDER

TACHOMETER

___

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+

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ADMIRAL

PANEL

NOTE:

WIRE

FOR

TO

BE

UPGRADED

#39144

NOTES:

THIS

PRODUCT

STARTER ExCESSIVE

SHUT

DCWN.

ENGINE

I

2.

AN

QN'OFF SWITCH

DISCONNECT

'WITH

A CONTINUOUS RATING

SWITCH THE

PINK

4

THE

GRAY

6ATTERY ATTATCHMENT

TO

AN 8 GAUGE

IS

PRQTI:.CTED

BY A MANUAL

CURRENT

THE

BUILDER/OWNER

ARE

INSTALLED

TO

PREVENT

SHOULD

BE

BATTERY

IN

AN

AT

PLUG 2 IS

AT

PLUG

RED NEED

10

BE

•

GAUGE

OF

USED

2 IS

#1

#14

'--=;-0;;;;---'

TO

NOT

PRESTOLITE\LEECE-NEVILLE

SHOULD

WIRE WIRE

THE

WILL

FROM

SATTUY

U

WilL

MUST

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INSTALLED

EMERGENCY

175

AMPS,

MAKE UNUSED UNUSED

MITSU81SHI

GRA

CAUSE

BE

OR AND AND

RESET

THE

SURE

BETWEEN

AND

AT

BREAK

SHOULD SHOULD

",OUltO

AC

.14

CIRCUIT

BREAKER LOCATED

BREAKER

TO

TRIP

INSTRUMENT PANEL.

BATTERY

AND

THE

Will

SERVE

AMP

ALT

ALT.

AND

DEVICES

STARTER

BOAT. A SWITCH

THIS FUNCTION.

CAPTAIN

THAT

THE

ELECTRICAL

THE

WHEN

LEAVING

12

voe

THE

CIRCUIT

BE

INSULATED.

I3E

INSULATED, ADMIRAL PANEL ONLY,

50

90

AMP.

TA,

eRtl

THE

ENGINE

AND

PANEL ONLY,

NEAR

WIRING,

TO

THE

Will

SEAWATER.

THI$

AND

O.P.

GAUGE

GNO

PRESTOllTE

#

14

CAPTAIN

PANEL

LAMP TEST

sw.

+

51

AMP

STANDARD 638 I:!l. 1088

ALTERNATOR

63C

I:!l.

D. & 108C·D.

liB

ON.

THE

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ALE

CONNECTOR

ON

THIS SIDE

72

AMP

PROPULSION

51

AMP

ALL

RED

ALI

"v'''-L~~H_.M..~e_

Engines & Generators

28

OPT I ONAl

135A. 160A,

liOA.

0:

63C

n:

ALTERNATORS

LESTEK

ALTERNATORS

718

II

IlZ8J;b

198ft

XI

®

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MARINE

ENGINE

+

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STARTER

M

GLOWPLUGS

ALTERNATOR

q,

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10...'<11:

r:>

'<11:"

-

TO

THE

'B'

TERM.

OF

KETSWITCH

TO

THE

START

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wu

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o

TO

THE'S'

TERM.

OF

KETSWITCH

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I-

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en

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TERM.

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THE

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TO

THE

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OF

TERM.

THE

ALARM

BUZZER BUZZER

OF

TERM.

THE

'P' OF

ALARM

1-.¥'IWESTERBEKE

• Enqines & Generators

TO

TERM. THE

THE'S'

OF

TACH

TO

TERM.

W.

T.

THE'S'

OF

GUAGE

LIFT

WATER

TO

THE

TERM.

THE

ALARM

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TO

THE

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TO

THE

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TO

THE

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THE

'B'

TERM.

OF

KEYSWITCH

CA)~;

TO

THE'S'

TERM.

OF

KEYSWITCH

=:

TO

THE

'5'

TERM.

OF

W.T.

GUAGE

fill

-0

THE

"P'

TERM.

OF

ALARM

BUZZER

o

THE

'C'

TERM.

OF

ALARM

BUZZER

iiJl'n

Q~

TO

THE

'I'

TERM.

OF

KEYSWITCH

iii

TO

THE'S'

TERM.

OF

TACH

o

THE

'.'

TERM.

OF

ALARM

BUZZER

il

'I

0-1

0

..

Ii

0

:0

,.,

'"

110

WHT

I

114

GRH

110

RED

114

PUR

114

VEL

114

L T.

BLU

114

TAN

110

RED/WHT

114

BRH

114

PINK

..

...

r----

~

~~I

I~I.,~

;;l

;;;

I

I~

"" <

10

-<

I a I-I..J

~

n I -

II

I

;::

I

:I:

I

!

:e

:~~

~

-

.....

:II

:s:

n

-

Z

;!:i

G:t

:a:-

:Pi

11:1

:a

...

-

I~E

-

:e-

Z

z

G:t

m

:e-

:II

:=

:e-

m

..

a:

z

~~E

0

n

m

:0

::z:

~

,.,

-

'"

-t

~~

=

Z

en

......

=

m

eo,)

en

=

01

-

»

II!

I

t

The

following relating lems,

and

troubleshooting

to

engine

service,

the

recommendations

the

table

describes

probable

to

overcome

ENGINE

certain

problems

causes

of

these

problems.

TROUBLESHOOTING

NOTE:

The

engine s electrical system

prob-

ampere the

back

the

same

manual reset circuit breaker located

of

the

engine.

The

preheat solenoid

bracket.

is

protected

by a 20

on

a bracket at

is

mounted

on

No

panel

indications;

or

fuel

pump

and

PREHEAT

button

OK;

solenoid

cranks,

fuel

solenoid

can't

runs

not

charging

is

not

be

down.

is

on

START engagement.

START indications fuel

Engine start,

Engine

Battery

Problem

fuel

not

working

button

is

depressed,

is

depressed;

starter

solenoid

functioning.

but

does energized.

stopped.

solenoid

(key

is

depressed).

no

starter

panel

OK;

not

switch

Battery

1. 20-amp

2.

10-amp

3. preheat

4.

Loose

5.

Preheat

1.

Connection

2.

Gear

3.

Faulty Faulty

4.

5.

Loose Low

6.

1.

Poor Defective

2.

Faulty

1.

Preheat

2.

Low

3.

Faulty

1.

Disconnect

2.

Fuel

3.

1.

Oil

pressu

High

2.

Low

3. Poor

4.

DC

altemator

5.

(tachometer DC

charge

1.

Alternator

2.

Probable

switch

not

circuit

breaker

tripped

solenoid

battery

connections.

solenoid

to

solenoid

shift

not

in

switch. solenoid. battery

connections.

battery.

connections

fuel

solenoid.

fueling

system.

solenoid

battery

power.

DC

altemator.

fuel

shut-off

run

solenoid

re

switch.

resistance

battery

leak

leak.

connections.

not

circuit

drive.

Cause

on.

tripped.

on

not

operating.

faulty.

neutral.

to

fuel

solenoid.

faulty.

cable.

will

not

de-energize.

to

ground.

charging

operating).

faulty.

1.

Check

2.

Reset

circuit

3.

Check preheat

4.

Check engine

5.

Check

1.

Check

2.

Gear

HURTH

3.

Check

4.

Check

5.

Check

6.

1.

Check

2.

Check

fuel

1.

Check

1

a.

Check

1b.

Fuel

fuel

2.

Check

3.

Switch

3a.

Replace

1.

Remove

2.

Check off

3.

Manually solenoid

1.

Observe is

2.

Check lines. after

3.

Check

4.

Check corrosion

5.

Check

DC

1.

Perform

Testing

2.

Check for volts

Verification}Remedy

switch

and/or

breaker,

if

and

check

the

voltage

solenoid.

(+)

connection

ground

stud. solenoid connection.

shift

must

HSW

TRANSMISSIONS).

switch

with

that

12

volts

battery

connections.

battery

charge

connections. that

12

run

filters system.

the

not

ELECTRICAL

loose

volts

solenoid.

that

fuel

for

air

in

clogged.

solenoid.

to

combine

batteries.

Exc.

connection

fuel.

disconnect

at

the

injection

if

gauges

running.

Test

wiring.

Insert

(Do

not

start

short

is

located.

all

wires

cable

connections

connections,

DC

voltage

the

Battery

drive

belt

connections.

are

present

battery

connections.

breaker

trips

again,

circuit

for

both

at

and

to

starter

Check

"S"

terminal

be

in

neutral

ohmmeter.

are

present

state.

are

present

valves

are

open.

fuel

system.

Replace

house

and

at

shut-off

the

12

pump.

and

panel

the

oil

pressure

sensitive

engine.)

for

temperature

at

check

belt

SYSTEM/ALTERNATOR.

check

Charging

tension;

alternator

Check

at

the

Exc.

shorts

to

after

the

solenoid

battery

cable

for

voltage.

(see

NEUTRAL

at

the

at

the

Bleed

air

filters

and

start

batteries.

alternator;

lever.

Pull

volt

connection

lights

are

(0 -.25

Remove

rise

battery

for

tension,

of

generator

Circuit.

should

output

terminal.

check

ground.

breaker

and

connections.

solenoid

(+)

connection

from

bleed

repair

lever

activated

switch.

amp)

connections

to

locate loose

test

charging

with

voltmeter.

preheat

solenoid

on

the

(-)

connection

SWITCH

connection.

on

fuel

system.

air

from

alternator.

back

to

close

to

the

fuel

when

meter

in

battery

and

the

fault.

connections,

alternator.

circuit.

turn

freely.

Ensure

to

under

the

run

engine

replace

See

Check

12

(continued)

~

Engines & Generators

31

ENGINE

TROUBLESHOOTING

Engine

slows

Engine

overheats/shuts

Engine

alarm

Engine

alarm

Exhaust

smoke

Problem

and

stops.

sound

pulsates.

sounds

continuously.

problems

down.

Fuel

1.

2.

Switches or

disconnected.

3.

Fuel

20

Amp

4.

Exhaust

5.

6.

Water

7.

Air

Raw

1.

2.

Coolant

1.

Loss

2.

Oil Engine

1. High

2. too

Blue

1.

White

2.

3.

Black

Probable

lift

pump

and/or

starvation.

circuit

system

in

fuel.

intake

obstruction.

water

not

circulating.

of

oil.

pressure

switch.

coolant.

temperature

Iowa

temperature.

smoke.

Cause

failure.

wiring

loose

breaker

tripping.

is

restricted.

circulating.

switch

opens

at

VerificationJRemedy

1.

Fuel

lift

pump

should

pump

with

spare.

2.

Inspect

wiring

Inspect

switches

Check

fuel

3.

4.

Check Ensure cause

5.

Check

exhaust Pump

6.

bleed

7.

Check

1.

Raw

2.

Obstruction

2a.

Thermostat -remove

Replace

2b.

Loss

for

2c.

Broken

2d.

Air

bleed

1.

Check oil

2.

Replace Check

1.

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.

supply,

for

high

breaker

tripping.

for

blockage,

elbow.

water

fuel

system.

air

intake

water

pump

thermostat.

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add

dipstick,

drain

hose oil

pressure engine for

satisfactory

with

ohmmeter,

grade

is

the

is

running

injector

grade

burn

incomplete

air

system;

timed

of

air -check

make a distinct

for

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

from

fuel

tank(s);

filter

cartridge.

failure.

Check

at

raw

water

intake

and

hoses,

belts -tighten/replace.

run

engine

coolant

as

needed.

look

for

oil

switch.

level.

operation

replace

engine

with

cold.

incorrect

fuel.

due

proper

air

injectors

air

intake

leaks

oil.

injector

to

combustion

intake).

connection.

coolant

of

overfilled

exhaust).

or

of

for

check

ticking

and

loose

operation.

fuel

draw

sensitive

hose,

change

impeller -replace.

or

test

in

and

if

engine

high

or

valves,

and

connections.

lift

pump.

during

operation.

to

heat

carbon

filters

raw

water

hot

water.

hose

clamps,

open

the

at

oil

filter

with

switch

faulty.

oil

(oil

is

timing.

back-pressure

(check

or

poor

air

filter.

sound.

Replace

which

would

buildup

at

and

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 is other than what is normally indicated by the gauge when the instrument panel is energized, the first step is to check for 12 volts DC between the ignition (B+) and the Negative

Assuming that there is 12 volts as required, leave the instrument panel energized and perform the following steps:

1.

Disconnect the sender wire at the gauge and see gauge reads zero, which is the normal reading for this situation.

2. Remove the wire attached to the sender terminal at the

sender and connect it to ground. full scale, which is the normal reading for this situation.

(B-)

terminals

of

the gauge.

See

COOLANT

if

the gauge reads

~

TEMPERATURE

If

both

AND

of undoubtedly conductor from the sender to the gauge or with the sender.

If

either

probably defective and should be replaced. Assuming the gauge is

the

sender to the sender terminal at the gauge for continuity. Check that the engine block is connected to the ground.

Some starters have isolated ground terminals and battery is connected to the starter (both plus and minus terminals), the ground side will not necessarily be connected

to the block.

WESTERBEKE

Engines & Generators

32

OIL

PRESSURE

GAUGES

the above gauge tests are positive, the gauge is

OK

and the problem lies either with the

of

the above gauge tests are negative, the gauge is

OK, check the conductor from the

if

the

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 meter circuit operates on volts alternator charging voltage supplied to the (+) terminal on the

back'ofthe

The tachometer circuit operates on 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 terminals.

1.

2. Voltage not present - trace

Tachometer

Check for the proper terminal and (-) terminal with the engine running.

1.

2. AC voltage not present - check for proper alternator DC

3. Check for AC voltage at tach terminal

4. Check electrical connections from tachometer input ter-

Tachometer

1.

2. Check for good ground connection between meter (-) ter-

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

of

the diodes in the alternator and supplied to the

meter

Voltage present - meter is defective - repair

nections for fault. (Jump 12 volts DC to meter terminal to verify the operation.)

Inoperative

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

output voltage.

ground.

minal to alternator connection.

Sticking

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

minal and alternator.

alternator pivot bolt.

METER

One circuit operates the hour meter and the

12

instrument.

AC

voltage 6-8 volts, fed

of

the two circuits in a tachometerlhour

DC

voltage between (+) and (-)

or

replace.

(+) and (-) electrical con-

(+)

AC

voltage between tachometer input

on alternator to

NOTE:

Current

dial

to

set

calibrating screw

IDLE

SPEED

&

TACHOMETER

Checking

NOTE:

In

the

tachometer

engine ~ rpm

model tachometers

the

tachometer

is

then

to

used for fine

use a coarse

the

crankshaft pulley

tuning.

adjustment

AC

ADJUSTMENT

CHECK

the

idle

speed

a new installation having new instrument

may

not always

This

calibration should

(New

Installation)

be

correctly calibrated

be

checked

rpms.

(-)

INP

VOLTAGE

panels,

in

all

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

Start and idle the engine.

2.

Aim the light

3. confirm the engine speed. Check the instrument panel tachometer reading. Adjust the tachometer using the instrument coarse adjustment to calibrate the instrument reading to the closest is showing. Then use the fine calibration adjustment to bring the instrument to the exact reading as the photo tach.

4. Adjust the idle speed specified value.

of

suitable reflecting tape on the

of

a photoelectric type tachometer.

the tachometer onto the reflecting tape to

in

the panel

R.P.M. that the photo tach

if

the engine speed is not within the

The

)

TERMINAL

to

the

new

by

Tachometer

a. With a hand-held tach on the front

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

b.

Adjust the tachometer with a small Phillips type screwdriver through the calibration access hole in the rear the tachometer. Zero the tach and bring it to the rpm indicated by the strobe or the hand tach. (Verify the rpm at idle and at high speed rpm,). (Adjust the tach as needed.)

Inaccurate

--..

idle,

of

the crankshaft pul-

of

Engines & Generators

33

ENGINE

ADJUSTMENTS

ADJUSTING

1.

Loosen the locknut on the idle adjustment bolt on the fuel injection pump.

2.

Adjust the bolt so that the throttle control lever will hold the engine at a quiet idle.

3. Tighten the locknut.

4. Race the engine several times to ensure the idle speed remains

NOTE:

tachometer mechanical or strobe-type tachometer at shaft.

See

THE

as

set.

Should

the

engine

readings

TACHOMETER.

IDLE

rpm

as

shown at

SPEED

[750 - 1000 RPM]

be

in

question,

the

instrument panel

IDLE

verify

the

engine

crank-

ADJUSTMENT

with

BOLT

----

ENGINE

STOP

POSIT/ON

STOP

CONTROL

FUEL

The optional fuel shutoff solenoid allows the engine to be shut down using the instrument panel key switch. The solenoid has been factory set and does not require adjustment.

CABLE

SHUTOFF

SOLENOID

[OPTIONAL]

STOP ENGINE

ADJUSTMENT

CABLE

CONTROL

DOWN.

SO

WILL

a

\

THAT

SHUT

DRIVE

Proper inspection, service and maintenance is important for the efficient operation

Drive Belts under MAINTENANCE

Drive belts must be properly tensioned. Loose drive belts will not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pull the alternator out tor to wear out prematurely. Excessive drive belt tension can also cause rapid wear of oil on the belt can cause belt slipping, resulting ating temperatures and tachometer variations.

The drive belt is properly adjusted no less than (12rnrn) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span A spare belt or belts should always be

Adjusting

1.

THE

2.

3.

4.

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

BELT

ADJUSTMENT

of

the drive belts

of

your engine (see

SCHEDULE).

of

alignment and/or cause the alterna-

of

the belt and reduce the service life

the coolant pump's bearing. A slack belt or the presence

if

the belt can be deflected

3/8

inch (IOrnm) and no more than

carrie<j

on board.

A

WARNING:

drive

belt's

Loosen the alternator adjusting strap bolt and the base mounting bolt.

With the belt edges.

Pivot the alternator on the base mounting bolt to the left or right as required, to loosen or tighten.

Tighten the base mounting bolt and the adjusting strap bolt.

recheck the belt tensions.

tension

Belt

Tension

lo()se,

Never

while

inspect for

attempt

the

engine

wear,

to

check

or

is

in

operation.

cracks and frayed

adjust

in

high oper-

112

inch

of

the belt.

of

the

OPTIONAL

FUEL

SOLENOID

RECOMMENDED

Model

44AJFOUR 44BIFOUR

35CITHREE 1000-1200 2500-3000 35DITHREE

Engines & Generators

34

RPM

RANGE

Max.

Idle

RPM

800-1000

800-1000 2000-2500

1000-1200 2000-2500 2900-3000

Cruise

RPM

2500-3000 3500-3600

RPM

. 2900-3000

3500-3600

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be below

TESTING

Make certain the oil level (dipstick) is at the correct level and the air intake filter is clean. The battery and starter motor

must also be in good condition.

1.

2. Move the control lever to a position for shutting off the

3. Remove all the glow plugs from the engine and install

ENGINE

Warm the engine to normal operating temperature.

fuel. (Disconnect the wires used).

the compression gauge/adapter combination to the cylinder on which the compression is to be measured.

TESTING

COMPRESSION

if

ENGINE

peiformed by a competent engine mechanic. The information

is

provided

a fuel shutdown solenoid is

to

ADJUSTMENTS

assist the mechanic.

COMPRESSION

PRESSURE GAUGE

FUEL

INJECTORS

In case

of

severe vibrations and detonation noise, have the injectors checked and overhauled injection service center. loss

of

positive fuel pressure to the injection pump can result in injector faults. Since fuel injectors must be serviced in a clean room enviroment, it is best to carry at least one extra injector as a spare should a problem occur.

Before removing the old injector, clean the area around the

base

of

the injector to help prevent any rust or debris from falling down into the injector hole. out easily and is held in by carbon build-up or the like, work the injector side-to-side with the aid free it, and then lift it out.

The injector seats in the cylinder head on a copper sealing washer. This washer should be removed with the injector and replaced with a new washer when the new injector is installed.

Injector

to

Cylinder

Head

Poor fuel quality, contaminants and

Tightening

by

an authorized fuel

If

the injector will not lift

of

Torque

40

the socket wrench to

± 4

ft-lb

(5.5 ± 0.5

kgf-m)

ADAPTER

~WPLUGHDLE

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 Maximum

(3

kgf/cm2)

NOTE:

lfthe

repair

7. Re-install the glow plugs (use anti-seize compound on

the threads) and reset the fuel shut-off to the run position.

8.

Open the raw water seacock (thru-hull).

LOW

COMPRESSION

When low compression is found, determine the cause by applying a small amount plug hole. Allow the oil to settle.

Install the pressure gauge and repeat the above test. compression reading rises dramatically, the fault is with the rings.

If

with the valves.

A slight rise in compression would indicate a problem with both the rings and the valves.

pressure

427

psi

(30

kgf/cm2)

permissible

readings are below the limit, the engine needs

the compression valve does not rise, the problem is

difference

between

of

oil in the cylinder

at

290

rpm.

cylinders

is

42.7

thru

psi

the glow

If

the

FUEL

INJECTOR

Engines & Generators

35

NOTE:

ments below

be

is

ENGINE

WESTERBEKE

performed by a competent engine

provided

to

ADJUSTMENTS

recommends

assist

the

that

mechanic.

the

following engine adjust-

mechanic.

The

information

VALVE

Make the following adjustments when the engine is cold.

1. Remove the cylinder head cover.

2. Slightly loosen the cylinder head bolts and retighten them

FRONT

3. Find top dead center compression position for No.1

(a) Turn the crankshaft until

CLEARANCE

to the specified torque in the number sequence shown below.

Tightening

•

piston by using the procedure that follows:

ADJUSTMENT

Torque

04

06

012

02

01

44

35

FOUR

65

THREE

± 4

Ib-ft

0'11

(88

os

± 5

Nm)

IDe mark on the crankshaft

pulley is aligned with the mark on the timing gear case.

(b) With No.1 piston at top dead center on the compression

stroke, the rocker arms will not be moved when the crankshaft is turned approximately

If

the rocker arms move, No.1 piston is at top dead

(c)

center on the intake or exhaust stroke. In such a case,

turn the crankshaft 360

rotation again. No.1 piston is now at top dead center on the compression stroke.

4. Loosen the lock nut for the adjusting screw. With a feeler gauge inserted between the rocker arm and valve cap, adjust the valve clearance by turning the adjusting screw. Make certain to adjust all the valves.

0

in the direction

~~

200 in both directions.

of

engine

0.25mm (0.0098

INCHES)

INTAKE & EXHAUST

TOC

(TOP MARK AND

NO.4

DEAD

FOR

PISTONS

CENTER)

NO.1

\~

\

TOC

MARK

NO.2

AND

FOR

NO.3

PISTONS

5. Install the cylinder head cover.

Head

Cover

Bolt

Torque

2 -3

ft-Ib

(0.3 -0.45

m-kg)

Engines & Generators

·36

J.S.

AND

B.W.

DESCRIPTION

The transmission's gear ration is 2.47 to transmission rotates opposite to the engine when in forward gear. The transmission transmits its power with case-hardened helical gears and, in reverse, an intermediate gear. The reversing process is carried out by a servo double disc system. For safety reasons, the transmission is lubricating oil for shipment. Before leaving the factory, each transmission is thoroughly tested with oil in the transmission. This testing, among other things provides all parts with a coating

viding reliable protection against corrosion for at least one

year

if

the transmission is properly stored.

The transmission is an immersion-lubricated type. Fill the

transmission up to on the dipstick with

oil exclusively. Multigrade oils are not to transmission. may have an

of

oil. This oil acts as a preservative, pro-

or

near the top

SAE

20W/20

DO

NOT

mi~

API specification

giades

of

1.

This manual

NOT filled with

the internal

of

the machined notch cut

or

SAE 30 weight engine

be

used in this

of

oil! Lubricating oils

CF

or CG-4.

LUBRICATION

The oil capacity for the transmission is approximately 1.0

quart (1.0 liter). Check the oil level daily after the engine has

been warmed and stopped. The oil level should be main-

tained at the top

the dipstick is completely inserted into the transmission hous-

ing. Make sure the two

good shape. These

of

the machined flat on the dipstick when

O-ring gaskets on the dipstick are in

O-rings will keep the dipstick in place.

TRANSMISSIONS

If

the throw distance (or travel) short, the gear box lever cannot fully engage the transmission into

FORWARD

mission's internal clutches will wear prematurely and the

transmission may over heat and eventually fail.

Excessive throw distance in the remote control level is not detrimental to the transmission. Note that the position remote control lever should align with the ing on its bracket when the transmission is really in NEUTRAL.

or

REVERSE.

.

JS

GEAR

SHIFT

f.>

CABLE.

REVERSE

GEAR

/

d

of

the remote cable is too

In this situation, the trans-

NEUTRAL

BOX

SHIFT

LEVER

.

NEUTRAL

of

the

mark-

FORWARD

Change the transmission oil after the first 25 hours operation and thereafter every imum. The transmission has a 6 plug for draining the oil. drain from the transmission, warm the oil by running the engine in This oil may also dipstick opening so the oil may oil temperature must not exceed

NEUTRAL

b~

for approximately 10 to 15 minutes.

removed by attaching a pump into the

250 hours or once a year, min-

mm

Allen Hex wrench drain

To

make sure most

be

sucked out. The operating

250°F (120°C).

of

the oil will

of

engine

CONTROLS

The only controls required to operate the transmission is a single level remote controlled cable. The cable should be attached to the gear box lever using the cable bracket supplied with the unit. Both the gear box lever and the remote control

when the cable' is the remote cable an equal throw distance to shift the gear box into

FORWARD position without running out 1-112

inches the transmission's gear box lever to each positions.

lever must be in the

attached to the gear box lever. This allows

or into

REVERSE

of

cable throw from the

NEUTRAL

from the

of

cable. Allow approximately

NEUTRAL

of

the two drive

position

position on

SHIFTING

To

shift the transmission fron

exert a

heavy push to the remote control lever. A gentle throw

may not carry enough force to actually shift the transmission's internal gears. A gentle throw is signalled by the transmission not engaging into the desired drive. Make sure the remote control lever is lubricated at least once each operating season. Shift the transmission while the engine is running at

1200 rpm or below.

A

CAUTION:

gear

box

this

plate transmission ensure

equal Loosening transmission

lever

and

of

has this

NEVER

cover

the

actuating

been

throw

cover's

warranty.

NEUTRAL

remove

from

transmission.

finely

distance

capscrews

or

loosen

level

inside adjusted of

internal

into FORWARD,

the

two-bolt

The

position

of

the

at

the

factory

mechanisms.

voids

the

of

to

I"""""WESTERBEKE

, Enaines & Generators

37

Revised

October

2001

J.S.

AND

B.W.

TRANSMISSIONS

BELL

SAILING

The transmission should while sailing. Leaving the transmission in sailing alleviates unnecessary drag propeller is able to freewheel (spin). However, mission is left in its transmission will not be damaged. (Leaving the transmission in

OPERATION

NEUTRAL

be

left in its NEUTRAL position

NEUTRAL

on

the vessel because the

FORWARD

is just good sailing practice.)

gear while sailing, the

if

the trans-

COOLING

The transmission is raw water-cooled. Raw water enters the transmission through a stainless steel inlet pipe located at the base

of

the bell housing. This water helps to cool the trans-

mission's lubricating oil.

HOUSING

RAW

WATER

COOLING

J.S.

and

B.W.

TRANSMISSIONS

J.S.

AND

B.W.

General

Gear

ratio

(optional)

Propeller (Direction

Propeller

Lubricating

Transmission

Capacity

ShaH

of

Rotation)

Oil

Sump

TRANSMISSIONS

Case-hardened intermediate by

servo

double

2.47

: 1

Right

hand -standard

See

propeller

SAE

20WI20

not

mix

grades

API,

CF,

CG-4,

1

qt.

(1

liter)

SPECIFICATIONS

helical

gears,

reverse

disc

recommendations.

or

SAE

of

oil

or

SJ.

with

gear.

Reversing

system.

transmission

30

exclusively

or

use

multigrades).

while

COUPLING

an

out

(Do

SERVICE

If

any seal on the transmission shows signs the transmission looked at by a qualified WESTERBEKE dealer. This problem, especially concerning the rear seal, is often contributed to an improper alignment transmission's coupling and the propeller shaft's coupling.

of

Disassembly mended. be done by an authorized WESTERBEKE service center.

the transmission in the field is not recom-

If

an overhaul

or

repair is needed, the work should

of

leaking, have

of

the

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 air vent is clear and when checking the fluid level look for signs

(fluid will appear as strawberry cream).

300 operating hours.

of

your regular

of

water contamination

Lay-up/Winterize

Storage requires special care. Follow these procedures:

NOTE:

This

operation will usually occur

water water cooling system

is

properly

when

the

winterized.

engine

raw

o Clean up the transmission and touch-up any unpainted

areas (use heat resistant paint).

~_~

Fill the transmission with

internal corrosion. (Extended.storage only, 12 months or more).

SAE

30 engine oil to prevent

o Loosen attaching hardware from the transmission output

flange and propeller shaft coupling flange before removing the boat from the water. Seperate 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.

NOTE:

If

the

transmission

(tWelve

months or

prevent internal

the

engine

back

of

more),

corrosion.

into

service.

the end fittings, cracks

of

the actuator rods. Lubricate

is

to

be

stored for a

it should

Reduce

be

topped off

the

oil level

.

long

with

before

or

time

cuts in

oil

putting

to

Engines & Generators

38

Revised

October

2001

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

BORG

WARNER

VELVET

DRIVE

OIL

"U~'Ll:fll'

OPTIONAL

TRANSMISSION

SHIPMENT

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

Before leaving the WESTERBEKE plant, each transmission undergoes a test run, with

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 continue to use this fluid. During the first 25 hours 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

CAUTION:

and

the

starting

correct

the

Be

size

engine.

Dextron III ATF transmission fluid.

if

properly stored.

FLUID

Dextron III and

certain

cooler

the

transmission

is

properly

installed

If

the

of

is filled

before

opera-

300

/44

FOUR

SHIFT

LEVER

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

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

ball located behind the transmission lever must work freely to center the lever in each position. The gear shift positions at the helm must be coordinated with those actuating lever through shift mechanism adjustments. An improperly adjusted shift mechanism can cause damage to the transmission. The shifting mechanism and transmission actuating lever should be free ensure proper operation.

Shifting

Place the gear shift in Neutral before starting the engine. Shifting from one selector position to another selector position may order. Shifts should be made at the lowest speed. Start the engine and set the throttle at idle speed; allow the transmission fluid to warm up for a few minutes.

Into

be

made at any time below 1000 rpm and in any

ONLY

POSITION

Gear

of

the Velvet Drive

of

dirt and well lubricated to

practical engine

Neutral

•

Move the gear shift lever to the middle position. You should

feel the detent. This centers the actuating lever on the trans-

mission. With the control in this position, hydraulic power is

completely interrupted and the output shaft sion does not tum.

NOTE:

Some

switch.

aligned

transmissions

Unless

the

in

neutral,

transmission actuating lever

the

are

equipped with a neutral safety

engine starter will not

of

the transmis-

is

perfectly

activate.

Forward

Move the gear shift lever to the forward position. feel the detent. The actuating lever on the transmission is the forward position. The output shaft and the propeller shaft move the boat in a forward direction.

You

should

in

Reverse

Move the gear shift lever to the reverse position. You should feel the detent. The actuating lever on the transmission is in the reverse position.

should move the boat in a reverse direction (astern).

NOTE:

Moving

Position

always away from

the engine! of

to

Forward

gear shift control

This

problem may

the

actuating lever

The

output shaft and the propeller

the

transmission actuating lever from Neutral

is

always toward

the

engine.

in

the

forward position, shut off

be

by

the

If

a result

gear shift

the

engine.

boat moves backwards

of

incorrect movement

lever.

Reverse

is

with

the

Engines & Generators

39

FORWARD

BORG

NEUTRAL

WARNER

VELVET

REVERSE

DRIVE

TRANSMISSION

D Clean off the transmission and properly dispose of the

fluid.

used

D Refill the transmission with DEXTRON III

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

ATF.

The

D Check the dipstick for the proper fluid level.

D Replace the oil filler cap and dipstick. (Press the dipstick

into place and tum clockwise until finger-tight.)

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

DAILY

OPERATION

TRANSMISSION

ACTUATING

LEVER

POSITIONS

D Check the transmission fluid. D Visually check the gear shift linkage and transmission. D Start the engine in neutral. Allow a few minutes at idle

for the fluid

NOTE:

noise from such

D Shift into

A

CAUTION:

cause

damage

throttle

on

the

transmission

to

warm.

Too

Iowan idle speed will produce a chattering the

transmission gear and damper

cases

the

idle

gear.

back

Shifting

to

the

to

idle

speed should be

gears

engine

when

and

damper

shifting

the

damper

above

plate.

gears

plate.

increased.

1000

will

plate.

rpm

can

Pulling

save

In

the

wear

INSPECTION

D Visually check for oil leaks at the hydraulic connections.

Check for wear on the hydraulic lines and replace worn.

D Lubricate the detent ball and shift cable attaclunents. D Inspect the shift linkage. D Inspect the transmission bolts; retorque

if

necessary.

if

A

WARNING:

engine

is

running.

hole . .This

Oil

Capacity

Approximately 2.5 quarts (2.36 liters) will

sions

to

the oil level have a direct relationship will

be

required angle of installation will make a difference in the quantity of oil required

MAKE

CERTAIN RUBBER SCREWED TIGHT

TO

HANDLE

Never

pull

out

the

dipstick

Hot

fluid

will

splash

could

cause

severe

burns.

fill

mark on the dipstick. Many variables

to

the oil capacity. Additional oil

to

fill

the oil cooler and the cooler lines. The

to

fill

the transmission.

THE

SEAL

IS

THE-_~!l<:

---;::::=:;I*tt~tt4::--MIN

while

from

the

fill

most transmis-

MAX

the

dipstick

A

CAUTION:

sion

shift

positions.

CHANGING

After the initial 50 hour change, the transmission fluid should

be

changed at every 300 operating hours thereafter or at winter haul-out. However, the fluid must be changed whenever it becomes contaminated, changes color, or smells rancid.

Clutch

failure

lever

does

not

THE

TRANSMISSION

fully

will

occur

engage

FLUID

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

drain into a container.

D Reconnect the oil cooler return line.

D Use a suction pump

through the filler cap/dipstick hole.

to

remove the transmission oil

the

if

the

detent

transmis-

ball

to

Engines & Generators

40

Oil

Temperature

A maximum oil temperature of 190°F (88°C) mended. Discontinue operation anytime sump ture exceeds

PRESSURE

An optional mechanical pressure gauge can the control panel transmission gear should indicate constant.

230°F (110°C).

GAUGE

be

to

constantly monitor the pressure of the

fluid.

A normal reading at 2000 rpm in forward

95 -120

Ib-in2 (6.7 - 8.4 kg-cm

is

recom-

oil

tempera-

installed at

2

)

and

be

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission maintenance housing clean, check routine, and change

Periodically inspect the transmission and

corrosion. Make certain the air vent checking (fluid

will

the

fluid

appear

level look for signs of water contamination

as

is

minimal.

the

fluid

level

as

the

fluid

every 300 operating hours.

and

strawberry cream).

Keep

the

exterior

part of your regular

the cooler for leaks

is

clear

and

when

Lay-up/Winterize

Storage requires special care. Follow these procedures:

o Drain the water

replace it with a proper mixture of antifreeze coolant.

NOTE:

This

raw

water cooling system

o Clean

o Fill

up

(use heat resistant paint).

the

transmission

vent internal corrosion.

o Loosen attaching hardware

output

flange removing the boat from and spray with lubricant.

o Inspect

Look for corrosion of the all

the

conduit, and bending of the actuator

moving parts.

from

the

transmission oil cooler

operation will usually occur

is

properly

the

transmission and touch-up unpainted areas

with

Dextron

from

and propeller shaft coupling

the

water.

gear shift cable, linkage, and attachments.

the

end

fittings,

when

the

winterized.

III ATF

the transmission

Separate

fluid

flange

the

flanges

cracks or cuts

rods.

Lubricate

and

to

engine

pre-

before

in

WARRANTY

Service manuals are available dealer.

For assistance, contact:

Richmond and

1208 Liberty, Tel.:

BORG

placed operation or fully reversing of shifting. Therefore torque loads and directional changes should be made failure

denied.

be

A

CAUTION:

occur resulting BORG related

If

any

problems occur with

TRANSMISSION TROUBLESHOOTING

NOTES

Old Norris Road

SC

(800) 583-4327

WARNER

on

its gears

at

was

caused

at

low

engine

in

damage

WARNER

is

torsional

from

your

BORG

Velvet

Drive

29657

is

aware of the shock loads that can

as

the

result of mechanical propeller

the

propeller blades while

low engine speeds.

by

a shock load,

System-related

speeds to

not

vibration

which

the

engine

responsible

of

the

If

it

is

any

warranty claim will

noises

or

can

cause

and/or

for

total

this

type.

transmission,

in

found

vibrations

transmission.

system-

see

this

WARNER

be

that a

gear

rattle

manual.

can

NOTE:

If

the

transmission

(twelve

fluid

OIL

The continued time, occur. following

1. Transmission

fail.

2.

Either case requires

1. Install a

2.

Refill

months or

to

prevent internal

before

putting

the

COOLERS

flow

of

erode

the

inside of

These internal cooler leaks will cause one of

two

problems:

fluid

and

be discharged overboard through

A

loss

of

transmission fluid will

The

raw

water will leak into causing contaminated

transmission will eventually

an

increase

new

the

transmission

fluid

oil

an

cooler.

is

to

be

more),

it should

corrosion.

engine back into

raw

water through

the

cooler causing cross leaks

will leak into

in

transmission

will appear

immediate response:

with

the

cause

the

transmission

as

fail.

DEXTRON III

stored for a

be

topped offwith

Reduce

service.

the

flow

the

fluid.

strawberry cream.

long

the

fluid level

cooler

will,

the

of

raw

water

engine exhaust.

the

transmission

fluid

This

ATF.

time

to

The

in

to

If water needs take several

Check your dipstick each time until it appears

transmission out

If need

A transmission cooler some waters, maintenance,

WESTERBEKE recommends having a spare cooler

has

contaminated

to

be cleaned out

fluid

changes

fluid.

the

fluid

lines that connect

the

transmission

the

attention of a qualified transmission service

circumstances, depending on operating hours, tropical

the

fluid,

the transmission

and

replaced with fresh

to

get rid of

Change the transmission

to

fails

to

shift properly, it

may

last

etc.

it might only last half that

the

the cooler.

ten

years or more but,

fluid.

contamination.

as

pure

filter

and

will

most likely

fluid

It

will

clean

facility.

in

time.

aboard.

Engines & Generators

41

ZF

MARINE

DESCRIPTION

The infonnation the TRANSMISSION applies

to

CONNECTION

HBW

recommend a flexible transmission flexibly deflections. The installation of a special propeller thrust bearing taken specified under SPECIFICATIONS However, additional torsional certain

Even coupling gearbox wooden output

mounted, is

by

to

with

bearings

boats

flange

below

is

specific

TROUBLESHOOTING SECTION

all

models.

OF

GEAR

gearbox

not required, since the propeller thrust will be

the

transmission bearing, provided

the

output shaft should be protected

loads.

vibration.

observe

the

or

"DRIVESAVER"

and

the

in

order

Special care should be taken

When using a universal joint shaft,

the

manufacturers instructions.

engine solidly

caused

by

or

where

the

stem gland

to

the

ZF Transmissions,

BOX

WITH

PROPELLER

connection between the

propeller shaft if

to

compensate for-angular

is

not exceeded.

mounted,

will reduce stress

hull

distance between transmission

is

the

distortions, especially

less

than

../"

the

use

about

ZF

the

engine

value

from to

prevent

of

flexible

in

the

800mm.

15M

TRANSMISSIONS

NOTE:

When

installing

is

not impeded

cable

or

rod

too

small

a bending

control

housing.

Refer

CABLES

transmission

loosening

moved

or

rod

between

actuating shift lever

lever,

for

amount

is

shorter,

in

tum,

slow

clutch

Checkfor proper lever travel at least

is

the

to

any

position required for

linkage).

the

actuating lever cover

lever

cable

or

the

with

travel,

between

and

B should be at least

the

inner pivot

of shift lever travel

and

is

recommended.

proper

would

and

clutch engagement or

is

make

in

shifting Bowden

sheaves,

support for shift threaded holes located gear

CONTROL

The

Upon be (cable not contact distance

The control the neutral position of should coincide

The shifting actuating positions A

30mm

A greater detrimental travel which, generation by

NOTE

the

transmission,

by

restricted movability

linkage,

to

suitable for single lever

retaining

rod

the

as

measured at the pivot point of

mean plate

by unsuitably positioned

radius,

cable

connections,

above

the

WESTERBEKE

screw,

Make

certain that

and

cover should

should be arranged

when

in

the

operating lever

neutral position of

the

neutral position

point.

clutch

engagement

premature

failure.

no

make

etc.

In

order

use

shift cover

parts

the

actuating

the

control

the

plate:

the

be

neutral

position.

on

the

35mm

for

is

in

no

However,

might

wear,

This

would

engagement

each

NEUTRAL

on

remote

shift

O.5mm.

at

control

this

and

if

excessive

N

certain

of

the to

the

two

top

of

list.

control.

lever

elements

lever

minimum

right

angle

lever.

end

the

outer

way

the

lever

be

1;>e

indicated

at

all.

season.

that

guide

mount a

the

can

does

to

The

console

the

and

impeded

heat

A

CAUTION:

the

actuating

shift1ever this

mechanism

transmission

The

lever

travel

from..-neutral

is

warranty

position

is

of

factory-adjusted

position A and

in

any

way

tampered

will

be

void.

the

mechanism

to

ensure

B.

with,

the

behind

equal

If

Engines & Generators

42

SHIFT LEVER

O.Smm MINIMUM

--

COVER

F

DISTANCE

ZF

MARINE

TRANSMISSIONS

INITIAL

All with the engine at the factory prior to delivery. For safety reasons the fluid is drained before shipment.

Fill the gearbox with Automatic Transmission Fluid (DEXRON II or up to the index mark on the dipstick. just insert the dipstick, do not screw into the case after the fluid level is checked and tighten. Do not forget the sealing ring under the hexhead Check for leaks and change the fluid after the first 25 hours, also make a visual inspection hoses, and shift cables.

FLUI~

FLUID

Change the fluid for the first time after about 25 hours operation, then every 250 operating hours or at least once a year or when you change engine

Removing

Push a suction pump hose down through the dipstick hole to the bottom allows, use the transmission drain). Remove the drain plug from the bottom drain into a container, then reinstall the plug with its sealing washer. Wipe down the transmission and properly dispose the used fluid. After running the engine, shut down and recheck the fluid level.

Drain

NOTE:

drain plug sealing washer. The drain plug this sealing washer.

OPERATION

HBW

marine transmissions are test-run on a test stand

DEXTRON III). The fluid level should be

To

check the fluid level,

it

in. Screw the dipstick.

of

the dipstick.

of

the coupling, oil cooler and

"

DIPSTICK

FLUID

LEVEL.

Intt,l

I

~

"

DRAIN

.

I

CHANGE

oiL

the

fluid

of

the housing and suck out the fluid. (If space

of

the transmission and allow the fluid to

plug

torque

When changing the fluid, take care not to lose the

20 -25

fUlbs

will leak without

nl'\lllollYllolollON

OPERATING

of

OPERATING

The maximum permissible ATF temperature should not exceed 230° (110°). This temperature can only be reached for a short time.

A

CAUTION:-"

too

high,

transmission

LOCKING

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

of

position corresponding to the direction

WHEN

Rotation being sailed, being towed, or anchored in a river, operation ing the battery), will have no detrimental effects on the transmission

DAILY

TEMPERATURE

thtrtransmissio" fluid

stop

the

engine

immediately

fluid.

THE

PROPELLER

of

the propeller shaft by an additional brake is not

travel for this purpose. Never put the gear shift in the

UNDER

SAIL

OR

BEING

of

the propeller without load, such as when the boat is

of

the engine with the propeller stopped (for charg-

TOWED

temperature

and

check

of

travel

of

the boat.

as

well as

is

the

OPERATION

o Check the transmission fluid.

o Visually check the gear shift linkage and transmission.

o Start the engine in neutral, allowing a few minutes at

idle to warm the fluid.

o Shift into gear.

NOTE:

from the transmission gear

the idle speed should be increased

For additional information refer to the following text Transmission Section:

AND

Too

low an idle speed will produce a chattering noise

and

damper plate. In such cases

SHAFT

TRANSMISSION TROUBLESHOOTING.

ZF

TRANSMISSIONS

General

Gear

Ratio

(optional)

Note:

There

are a variety

of

gear

ratios

available.

Only a few

lubricating Propeller

Direction

are

listed.

Fluid

Shaft of

Rotation

COUPLINGS, MAINTENANCE

SPECIFICATIONS

(ZF

Standard hardened servo-operated

ZF

15MA

ZF

10MA

ZF

12MA

ZF

15MIV

ATF -Type A or

Right-hand listed.

Transmission)

helical

(1.88:1 (1.79:1) (2.63:1)

(2.13:1

rotation

gears,

multiple

or

2.63:1)

or

2.72:1)

Dextran

for

Case'

with

a

disc

- "

or

above

in

clutch

III

models

this

A

WARNING:

engine

is

running.

stick

hole.

This

Never

Hot

could

pull

out

fluid will

cause

severe

the

dipstick

splash

burns.

from

while

the

dip-

the

Engines & Generators

43

ZF

MARINE

TRANSMISSIONS

OPERATING

A

CAUTION:

too

high,

transmission

Normal operating temperature of the transmission should A maximum temperature of 266 reached for a short time.

Make certain there to

provide good ventilation and cooling.

TRANSMISSION

Coolers ZF

15M,

The cooler prevents

fluid.

However,

will,

in

leaks. A transmission cooler may last ten years or more

some circumstances, depending waters, maintenance, etc. it might only last half that

WESTERBEKE recommends having a spare cooler

TRANSMISSION

TEMPERATURE

If

the

stop

the

transmission

engine

immediately

fluid

and

fluid.

be

in the range

of

1220 F

(50"

C)

F

(130

0

to

C)

0

is

enough space around the transmission

COOLER

are

standard equipment

ZF

15MA,

ZF

15MIY,

is

a separate part of the transmission which

any

possibilities of coolant diluting the transmission

the continued

time,

erode the inside

for

the

ZF lOM;ZF

and

the

ZF

flow

of coolant thru the cooler

of

the cooler causing external

on

operating hours, tropical

temperature

check

the

fluid

b~

only

12M,

but,

time.

aboard.

in

0

C).

2120 F (100

may

25M.

is

MAINTENANCE

Transmission maintenance

housing clean, check routine, and change

Periodically inspect the transmission and corrosion. Make certain the air vent checking the (fluid will appear

fluid

level look for signs of water contamination

as

Lay-up/Wi.nterize

Storage requires special care. Follow these procedures:

o Drain water from the transmission oil cooler

with

a proper mixture of antifreeze coolant.

NOTE:

This

operation will normally occur

engine

raw

water cooling system

o Clean

up

the

transmission

(use

heat resistant paint).

o Fill the transmission

prevent internal corrosion (extended storage months or

more).

is

minimal.

the

fluid

level

as

the

fluid

every 300 operating

strawberry cream).

and

touch

with

Dextron III ATF

Keep

the exterior

part

of

your regular

hours.

and

the cooler for

is

clear

and

when

and

replace

when

the

is

properly winterized

up

unpainted

fluid

to

only,

leaks

areas

twelve

o Loosen attaching hardware from the transmission output

flange

and propeller shaft coupling removing and spray

the

with

boat

from

lubricant.

the

o Inspect the gear shift cable, linkage,

Look for corrosion of the end the conduit, and bending of the actuator

all moving

NOTE:

(twelve months or

fluid

before putting

parts.

lfthe

transmission

to

prevent internal

the

is

more),

it should

corrosion.

engine back into service

flange

water.

Separate

and

fittil').gs,

to

cracks

be storedfor a

be

topped offwith

Reduce

before

the

flanges

attachments.

Qr

cuts

rods.

Lubricate

long

the

fluid level

in

time

·PERIODICALLY EROSION

AND

INSPECT

LEAKAGE

FOR

Engines & Generators

44

For additional information ZF MARINE

ZF Industries

Marine 3131

SW

Lauderdale,

Fort Tel.:

(954)

Fax:

(954)

GEAR

US

Headquarters

42nd Street

581-4040 581-4077

FL

33312

'-t---GEAR

.

SHIFT

contact:

THE

MODEL

FITTING

720

HAS A BREATHER

ON

THE

TOP

OF

THE

CASE

PRM

--.rllD,"nrV

NEWAGE

MODEL

A

8MM

"

.'

SEAUNG

WASHER

MODELS

7/2"

HEX

80

HEX

.

PLUG

(MODEL

720

USES

PLUG)

. drain plug sealing

FULL

LOW

~

'~NOTE:

~

TRANSMISSIONS

80

AND

120

Push

a suction

to

the bottom of

allows,

from

the

and

allow

plug

with

properly

shut down

NOTE:

When

this sealing

A

WARNING:

engine hole.

DAILY

o Check

0 Visually check

o Start the engine

idle

0 Shift

from

the

idle speed should

GEAR

SHIFTING

The engine must be

selecting 120

are ideal

both

the

pump

hose

the

housing

use

the

transmission

bottom

dispose

of

the

fluid

its sealing

of

and

re-check

changing

washer.

the

transmission

to

drain

washer.

the

used

the

washer.

Never

is

This

running.

could

Hot

cause

OPERATION

the

transmission

the

gear shift linkage

in

neutral,

to

warm

the

fluid.

into

gear.

Too

low

an idle speed will produce a

transmission gear

be

at

idle. Pause

ahead

or

astern.

for

single lever engine controls,

throttle

and

the

down

and

drain).

into a container,

Wipe

fluid.

fluid

fluid,

The

drain plug will leak without

pullout

fluid

will

severe

fluid.

allowing a

and

damper plate.

increased

Transmission

gear shift at

through

suck out

Remove

(I"

down

After

level.

take

care

the

dipstick

splash

burns.

in

neutral

one

the

dipstick

the

with

then

the

transmission

running

not

from

and

few

chattering

models

time.

hole

fluid.

(If

space

drain

plug

sealing

washer)

reinstall

the

engine,

to

lose

the

while

the

dipstick

transmission.

minutes

In

before

PRM

controlling

such

at

noise

cases

80

the

and

INITIAL

Remove the dipstick transmission with

Model PRM80-1.0 Model

NOTE

filling with

Run the

CHANGING

Change operation, a year or make a coupling.

OPERATION

fluid

(ATF)

the

recommended capacity of

PRM

120-1.4 U.S. pints

Always clean the

fluid.

Replace

the

engine

to

warm up

engine,

re-check the

THE

the

fluid

for the

then

every 250 operating

when

you

visual

inspection of

and

fill

the

gear box

Dextron

U.S.

pint

area

the

fluid

TRANSMISSION

first

change engine

m.

Fill

fluid.

(0.6L).

(0.8L).

around the dipstick plug before

dipstick by screwing it

the

fluid

and

level.

FLUID

time after about

hours

oil.

Check

the

shift

cables

with

automatic

the

transmission

after

shutting

25

or at least

for

and

hours

leaks

shaft

down.

down

of

once

and

A

WARNING:

throttle

ahead

LOCKING

Locking of required: direction of in

the position corresponding

boat.

WHEN

Rotation of is

being

operation of

charging

transmission

to

or

astern.

THE

the

use

UNDER

sailed,

the

When

idle

and

pause

PROPELLER

propeller shaft

the

gear shift lever position opposite

travel

for

this

SAIL

the

propeller without

being

towed,

the

engine

battery),

will

shifting

purpose.

OR

BEING

with

have

gears,

in

neutral

by

an

additional

Never put

to

the direction of

TOWED

load,

or anchored

the

propeller

no

detrimental

bring

before

such

as

in a river,

stopped

the

engine

shifting

brake

your

the

gear

travel

when

as

(for

effects

is

of

the

well

on

not

shift

the

boat

as

the

Engines & Generators

45

PRM

NEWAGE

TRANSMISSIONS

CONTROL

NOTE:

shifting Bowden sheaves,

The

the actuating shift lever

CABLES

When

installing

is

not impeded

cable

or

too

small

control

cable or rod should be arranged

the

l:Jy

rod

linkage,

a bending

when

transmission,

restricted

l:Jy

unsuitably

radius,

in the neutral position. The

neutral position of the operating lever

coincide

should The

shifting

actuating positions A

30mm

for

with

the neutral position of

travel,

as

measured

lever,

between the neutral position

and

B should be at least

the inner pivot point

at

the pivot point of

35mm

TROUBLESHOOTING

Problem

Excessive Excessive

Difficulty

Escape when

Fluid

noise noise

needs

in

moving

of

pressure

dipstick

at

low

at

all

constant

lever

from

is

removed

speeds

topping

control

gearbox

off

make

movability

positioned

etc.

at

on

the

control console

this

and

for

Probable

1.

Engine

1.

Defective Shaft

2. Prop

out

3. Power

1. Ruid

leak

2.

1.

Poor

installation

Faulty

2. Defective

1. (Model

MODELS

certain

that

of

the

guide

right angle

lever.

end

the outer

idle

speed

coupling

misalignment

of

balance

too

high

cable

breather

120)

the

and

Cause

too

of

cable

to

low

80

AND

. A greater

detrimental travel which; generation

by

NOTE

120

ACTUATING SHIFT

LEVER

amount

is

shorter,

in

tum,

and

slow

clutch

Checkfor

1.

2.

3.

1.

2.

1.

2.

1.

N

NEUTRAL

30

'

I r

\ : I '

< !!)1' 0

~,

~D'

~.

\

of shift lever

and

is

recommended.

proper

would

mean

clutch

plate

engagement

proper

lever

Verification/Remedy

Increase

idling

InspecVreplace

Check

alignment

Remove,

check

Compare

engine

Inspect

seals, InspecVreplace Check

alignment

Inspect

breather

WESTERBEKE

I

35·.......:

.1

30'11

..

J!

#~t:I;::1

/'

. i

travel

==:=::I~

II

SHIFT

is

in

However,

clutch

engagement

premature

failure.

or

travel

speed

coupling

with

pitch,

and

drain,

coupling

with

(Model

dealer

no

feeler

balance

transmission

check

feeler

wear,

This

would

engagement

at least

if

necessary

gauge

and

weight

data

for

fluid

leaks

if

necessary

gauge

120),

contact a Distributor

CABLE

no

way

if

the

might

excessive

be

at

each

AND

BRACKET

lever

be

impeded

indicated

all.

season.

or

heat

your

MAINTENANCE/SERVICE

Make certain the transmission

If

the

fluid

should become contaminated

suffers

gearbox

must

be

major mechanical damage, the gearbox

thoroughly

flushed

to the correct specifications. . NEWAGE

the

Atlantis 418 Topsfield, Tel: Fax:

Hamilton 1111 Seattle, Tel:

Fax:

Transmission 223 P.O.

Ft.

Lauderdale,

Tel:

Fax:

Or

TRANSMISSIONS

world.

Listed here are those in the United States.

Marine

Gear

Boston

Street

MA

978-887-0001

978-887-5599

Jet

NW

Ballard

WA

206-784-8400

206-783-7323

Southwes133

Box

21086

954-467-1540

954-467-1525

contact your

01933

Way

98107

.Marine

FL

Supply

Court

33335-1086

Westerbeke

Inc.

fluid

out

dealer.

and

LTD.

is

changed

re-filled

has

annually.

by

water or the

with

distributors around

fresh

fluid

If

a major

problem

should

occur, dealer or a NEWAGE distributor. warranty rights, gearbox without

TRANSMISSIONS

or your

WESTERBEKE

do

not undertake repair

first

contacting NEWAGE

liMITED

or a NEWAGE distributor

dealer.

Warranty

Newage Transmissions worlananship under twenty-four

All

and

transmission

months.

PRM

Transmissions

maintained.

will

limited

be

free

normal

from

use

must

warrants

be correctly

contact your

To

avoid prejudicing

work

that

defects

in

material

and

service

installed,

Westerbeke

on

the

all

PRM

Newage

and

for a period

aligned,

or

Engines & Generators

46

TRANSMISSION

TROUBLESHOOTING

I

CONTROL

The improper problems rather

PRM

cable If

you shut level, the

full neutral, observe is stiff and

CABLES

majority

the

try

of transmission difficulties arise

clutch

With

than

from

clutches, adjustments.

experience

engine

then

have

range -from

into

full

the

actuating lever

to

operate,

again.

adjustments (manual transmissions) or

control cables (hydraulic transmissions)

problems

in

particular, are

operating problems

down.

a helper move the cockpit shift lever

reverse,

break the cable loose

If

it

is

still stiff, check

excessively tight bends,

Problem

Transmission Fails

Transmission but

fails

Delay

only

Transmission

Chattering mainly

Boat

Oil

Leakage.

to

move

to

propel

of

gear

after

an

transmission

at

low

fails

to

gears

cannot

into

gear.

shifts

into

gear,

the

boat.

engagement

increase

in

speed.

noise

becomes

engine

attain

noise,

speed.

specified

with

the transmission

very

First check

neutral

to

and

back

on

the

and

check

be

shifted.

or

engages

louder.

max.

speed.

sensitive

with

the transmission,

the

transmission-fluid

full

forward,

to

neutral - while

transmission.

at

the transmission

the

cable for

any

linkage for

Probable

1.

Actuating

2.

Shifting unattached.

3.

Shift

lever

1.

Output

2.

Propeller Output

3.

Output propeller

Lever

1.

Refer

2.

Shift

level

Shift

lever

3.

1.

Damage to

wear misalignment driveshaft.

Beginning

2.

transmission running alignment

engine

The

engine

1.

vibrations a

·chattering"

Operating

1.

2.

Operating Corrosion

1.

Damaged

Misalignment

2.

as

a result of

itself.

to

improper

through

back

to

you

If

the

remote

kinks

or

binding.

Cause

lever

is

loose.

cable

is

broken,

Cable

radius

is

binding

coupling

is

not

shaft

is.not

coupling

is

tuming.

coupling

and

shaft

are

turning.

travel N to B not to

diagram.

travel

in

insufficient.

is

binding

starting

on

or

without

output.

temperature

sealing

flexible

fatigue,

possibly

between

damage

of

due

to

torsional

fluid,

of

transmission,

or

propeller

in

the

drive

noise

in

without

cooling.

at

radial

sealing

ring.~

of

output

bent

is

too

against

cover

tuming.

turning.

equal

to N to

against

cover

coupling

due

engine

bearings

overload,

or

generates

unit

which

the

transmission.

is

high.

ring

flanges.

A

new needed. out

of gear

make If the

have the

propeller needs thrust, the

shaft that

NOTE:

immediately authorized

or

severe.

plate.

A.

plate.

due

to

and

in

vibrations,

wrong

excessive

torsional

produces

and

shaft.

cable

and

perhaps a new

While the

sure

there's

transmission

a helper put it

professional

check

or,

it isn't stuck

If

you suspect a major problem

cable

using

the lever

no

passes

in

shaft;

if

attention.

to

see

you

if

you

have

in

the

contact your

marine

transmission

is

loose, on

binding

these

forward

the

shaft

still a folding or

"no

WESTERBEKE

Verification/Remedy

1.

Tighten

damping

bolt

2.

Check

the

cable,

reattach

3.

Detach

the

shift

Clearance

1.

Transmission

2.

The

coupling

on

the

pins

and

3.

Inspect A

folding

propeller

1.

Adjust Refer

to

2.

Check

3.

Check

1.

Check inspect engine.

2.

Transmission

Mount a flexible

1.

between A

higher

Inspect

2.

transmission. Wrong

1.

2.

Check Transmission

1.

2.

Check

cable

should

needs

bolts

propeller

shaft.

coupling

the

propeller.

propeller

may

be

cover

plate

SHIFT

LEVER

shift

lever clearance, alignment,

the

damper

Replace

if

needs

coupling

the

transmission

stiffness

the

damper

Replace

type

of

fluid.

cooler.

Inspect needs

alignment.

be

in

cable

adjust

inspect

Must

linkage

shift

the

side

inside

tests,

and

reverse

isn't

turning,

If it

does

have

a propeller

pitch"

position.

facility.

on

shifting

or

replace.

and

operate

0.02

in

(0.5mm).

professional

are

sheared

Tighten

bolts

as

necessary.

It

may

be

may

be

jammed. A variable

"no

pitch"

until

the

lever

TEXT

AND

length.

if

necessary.

flexible

plate

between

necessary.

professional

with

coupling

factor

might

plate

between

if

necessary.

Use

ATF.

coolant

professional

be

within

mechanism

the

transmission

of

the

transmission

the

case.

crank

the

while

the

turn but there's

on

feathering

in

your

transmission,

dealer

lever.

the

lever

attention.

or

the

coupling

or

replace

set

missing

or

damaged.

position.

is

exact

mid-position.

DIAGRAM.

See

SHIFT

LEVER

coupling.

the

transmission

attention.

another

stiffness

with

and

be

sufficient.

the

engine

Check

fluid

level.

hoses

and

coolant

attention.

0.003

in

(O.OBmm).

may

in

engine

and

you

observe

transmission

no

the

end

of

propeller,

or

an

by

hand.

is

Slipping

screws,

keys,

pitch

DIAGRAM.

If

noise

persists,

and

the

factor

the

driveshaft.

and

the

flow.

be and to

NOTE:

If

you

suspect a major problem immediately authorized

contact your

marine

transmission

WESTERBEKE

facility.

in

your

dealer or

transmission,

an

Engines & Generators

47

PROPELLER

RECOMMENDATION

CHART

44A

(40

hp/3600

35C

(29

hp/3600

FOUR

rpm)

THREE

rpm)

TRANSMISSION

RATIO

2.0:1

••....•..•............

2.47:1

.......•...•.........

2.72:1

....................•

2.99:1

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

2.0:1

.....•........•...•..•

2.47:1

•...............•...•

2.63:1

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

2.99:1

..•..................

PROPELLER DIAMETER/PITCH

170 x 10P. 170 x BP.

1BO x 11P.

1BO x 9P.

1BO x 13P. 1BO x 11P. 200 x 13P. 200 x 11P.

140x 140 x BP. 160 x 11P. 160 x 9P. 170 x 13P. 170 x 11P.

1BO x 13P.

1BO x 11P.

....•.................... 2

..••...................•... 3

.......•.••....•........ 2

..••....•....••........•.. 3

...............•.•.....•. 2

....•..................•. 3

.........•.............. 2

......•.....•.•..•.•..... 3

10P.

.•.....•...••.....•••..... 2

•........................•. 3

..•..........••........•. 2

........................... 3

......•....•..... : ....... 2

.••.........•••......•.... 3

.....••....•.....•......• 2

..•....•....•..........•.

PROPELLER BLADE

(RH)

Blade

Blade Blade Blade Blade

Blade

Blade Blade Blade

Blade

.3

Blade

44B

(39

hp/3000

35C

(31

hp/3000

FOUR

rpm)

THREE

rpm)

2.0:1

•....•........•.......

2.47:1

..•..•..............

2.72:1

•.......•..•........

2.99:1

...•....•...........

2.0:1

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

2.47:1

....•................

2.72:1

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

2.99:1

..•...•.............

NOTE:

For

reductions

factory

for

recommendations.

170 x 11P.

170 x 9P. 200 x 13P. 200 x 11P. 200 x 14P. 200 x 12P. 220 x 15P. 220 x 13P.

160 x 10P.

160 x BP.

1BO x 13P.

1BO x 11P.

200 x 12P. 200 x 10P.

220 x 13P. 220 x 11P.

not

included,

.........••............•• 2

•....•..................•.. 3

.......................•. 2

.......................•. 3

•....•••....•......••.... 2

•.•...............•••.... 3

•...........•.....•••.... 2

...•....••............... 3

•....•.....••......•..... 2

...•.........••.....•...... 3

.••....•.............•... 2

..•.........••... : •••.... 3

...........••............ 2

........•................ 3

...•...........••.......• 2

....•...........•........ 3

consult

the

WESTERBEKE

Blade

Blade Blade Blade Blade Blade Blade

Blade

Blade Blade Blade

Blade

Engines & Generators

48

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 accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own lay-up and recommissioning, or will serve as a checklist if

others do the procedures.

These procedures should provide protection for your engine/generator during a lay-up and also help familiarize

you with its 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 is hauled out

of storage severe strain on the propeller shaft or coupling or both, while the boat is taken out or put shaft has actually been bent apply to small boats that are hauled out not in use, unless they have been dry for a considerable period

Fresh

A 50-50 solution mended for use

This solution may require a higher concentration of antifreeze,

depending on the area's winter climate. Check the solution to make sure the antifreeze protection

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture. Operate the engine to ensure a complete circulation and mixture system. Then recheck the antifreeze solution's strength.

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.

Shaft

the water or moved from land to water, and during

in

the cradle. The flexibility

of

time.

Water

of

the antifreeze concentration throughout the cooling

Cooling

of

in

the fresh water cooling system at all times.

System

Use the correct grade

ENGINE LUBRICATING

"engine oil change".

Run the engine and check for proper oil pressure and make

sure there are no leaks.

of

inactivity. Others prefer to

Coupling

[Propulsion

of

the boat oftens puts a

in

the water. In some cases, the

by

these strains. This does not

of

the water when

Circuit

antifreeze and distilled water

is

adequate.

of

oil. Refer to the

OIL

pages

in

this manual for

Engine]

is

recom-

Fuel

System

Top off your fuel tanks with unleaded gasoline

or higher. A fuel conditioner such as stabilizer should be added. Change the element gasoline/water separator and clean the metal bowl. Re-install and make certain there are up

any spilled fuel.

Fuel

System

Top off your fuel tanks with No.2 diesel fuel. Fuel additives

BlOB

such as control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water seperator used in

your primary fuel filter/water seperator,

has one, and clean the seperator sediment bowl. Change the fuel filter elements on the engine and bleed the

fuel system, as needed. Start the engine and allow it to run for 5 -

10 minutes to make sure no air is left system. Check for any leaks that may have been created the fuel system during this servicing, correcting them needed. Operating the engine for 5 - 10 minutes will help allow movement equipment on the engine.

Raw

Water

Close the through-hull fitting. Remove the raw water intake hose from the fitting. gallon bucket check the zinc anode found the engine and clean or replace it any zinc debis from inside the heat exchanger where the zinc anode is located. Clean the raw water strainer.

Start the engine and allow the raw water pump to draw the fresh water through the system. When the bucket stop the engine and refill the bucket with an antifreeze 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 well as providing corrosion protection.

Remove the impeller from your raw water pump (some antifreeze mixture will accompany it, so catch it Examine the impeller. Get a replacement, cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover and gasket.

[Gasoline]

of

STABIL

no

[Diese~

OR

and

STABIL

of

the treated fuel through the injection

Cooling

Place the end

of

clean fresh water. Before starting the engine,

in

your area.

should be added at this time to

in

the system. Change the element

Circuit

of

in

the primary heat exchanger on

as

required and also clean

of

this mixture to be drawn

Once the bucket is empty, stop

gasoline

leaks. Clean

if

the fuel system

in

the fuel

this hose into a five

if

needed, and a

89

in

your

is

empty,

in

a bucket).

octane

in

as

A

CAUTION:

oil

in

the combustion chemicals internal

parts.

sump

over

depOSits

which

Do

not

the

combine

can

leave

lay-up

reduce

th~

engine's

period.

to

produce

the

life

of

old

Engine

harmful

your

engine's

engine

oil

and

Engines

49

Intake

Place a clean cloth, lightly soaked

opening shove the cloth out

recommissioning, and an attempt is made to start the engine,

you may need assistance note to remove the cloth prior to start-up. The thru-hull exhaust port can be blocked in the same manner.

& Generators

Manifold

of

the intake manifold to block the opening. Do not

and

of

sight.

of

Thru-Hull

(If

the servicing dealer). Make a

Exhaust

in

lubricating oil,

it is not visable at

in

the

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication and cleaning advisable, Make sure the battery connections are shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.

Cylinder

If

WES1ERBEKE recommends removing the glow plugs or fuel injectors for access to the cylinders. Squirting 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

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 through-hull exhaust port. to start-up!.

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the opening shove the cloth out sioning, and an attempt is need the assistance remove the cloth prior to start-up. port can be blocked in the same manner.

Motor

of

the starter drive pinion is

if

access to the starter permits its easy removal.

Lubrication

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

or"

injectors.

if

removing the injector"

~njector

Manifold

of

the intake manifold to block the opening. Do not

[Gasoline

and

of

sight.

of

a servicing dealer.) Make a note to

and fuel

"return

J

clqth in the

Make

a note to remove cloths prior

Thru-Hull

(If

made

Exhaust[Diesel]

it

is not visible at recommis-

to start the engine, you may

The

through-hull exhaust

line.

BAnERIES

If

batteries are to be left make sure they are fully charged, and will remain that way, to prevent them from freezing. the batteries will not remain fully charged, or that they will be subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

on

board during the lay-up period,

If

there exists any doubt that

Spare

Lay-up time provides a WES1ERBEKE engine to see

Parts

good

belts or coolant hoses spares kit and order items not used during the lay-up, to

SPARE

PARTS

need

section

replacement Check your basic

such

of

this manual.

opportunity to inspect your

if

external items such

on

hand, or replace those items

as filters and zinc anodes. Refer

as

drive

Recommissioning

The recommissioning

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

1.

Remove the oil-soaked cloths from the intake manifold

2. Remove the raw water the old gasket. Install the removed during lay-up (or a replacement, Install the raw water

3. Reinstall the batteries that were removed during the layup, and reconnect the battery cables, making sure the terminals are clean Check to make sure that the batteries are fully charged.

A

CAUTION:

and

eye

protection

batteries

can cigarette, open

all

electrical

4. Remove the spark plugs, proper tightness

emit

be

ignited

cigar,

flame

near

electrical

arcing

of

your

WES1ERBEKE engine after a

in the

PREPARATIONS

of

the lay-up procedures will

pump

cover and gasket. and discard

raw

water pump impeller

pump

cover

and

that the connections are tight.

Wear

rubber

gloves, a rubber

when

servicing

hydrogen,

by

Dr the

equipment

during

[gasoline].

a highly

electrical

pipe.

Do

battery

in

servicing.

wipe

arcing

not

smoke

being

the

vicinity

clean, re-gap, and install to

FOR

STARTING

need"

to be

if

required).

with a new cover gasket.

apron,

batteries.

explosive

Lead

gas,

acid

which

Dr a lighted

Dr

allow

an

serviced.

to

prevent

Shut

off

A

Warning:

highly-explosive arcing

Dr a lighted

smoke

Dr

serviced.

vicinity

to

Transmission

Check

or

change the fluid in the transmission as required.

Wipe

off grime and grease and touch up any unpainted areas. Protect the coupling and the output flange with an anti-corrosion coating. Check that the transmission vent is open. For additional information, refer to the

SECTION.

Lead

gas,

cigarette,

allow

an

open

Shut

off all electrical

prevent

electrical

[Propulsion

acid

which

flame

batteries

can

be

cigar,

ngar

equipment

arcing

Engine

TRANSMISSION

emit

hydrogen,

ignited the

by

electrical

Dr

pipe.

Do

not

battery

during

being

in

the

servicing~

J

a

Engines

5. Check the condition circuit and clean or replace the anode as needed. Note that

it is not necessary to flush the antifreeze/fresh water solution from the raw water coolant system. When the engine is put into operation, the system will self-flush short period advisable, as either an service, heat exchanger and clear any and all zinc debris from that area.

6.

Start the engine in accordance with procedures described in the this manual.

& Generators

of

to

inspect the

PREPARATIONS

of

the zinc anode in the raw water

time with no adverse affects.

end

of

season or recommissioning

area

where the zinc is located

FOR

INmALSTART-UP section

50

It

is

in

a

the

of

44A & 448

FOUR

ENGINE

SPECIFICATIONS

Engine

Type

Displacement

Aspiration

Combustion Bore & Stroke Firing Direction Compression Dimensions -inches

Engine

Weight Fuel

Inclination

Chamber

Order

of

Rotation

Ratio

Only

Consumption

TUNE-UP

Compression

Minimum Valve

Spilled Valve Engine

Valve

(engine Injector

Engine

Pressure

liming

(Static)

Seat

Angle

Speed

Seat

Angle

Clearance

cold) Pressure

liming

SPECIFICATIONS

Diesel,

(mm)

four-cycle,

cooled,

vertical

mechanism

107.3

cubic

Naturally

Swirl

type.

3.07 x 3.62 1 -3 -

4-2 Clockwise, 22:1

Height:

18.6

Width:

23.0

Length:25.6

331

Ibs

2.5

glhr

Continuous Temporary

in-line

..

inches

aspirated.

inches

when

viewed

inches

inches ( 584.2

inches ( 914.4

(150

kgs)

(9.7Itrlhr)

15°

25°

(not

four-cylinder,

(78 x 92

without

at

SPECIFICATIONS

427

psi

(30

psi

(27

Opens Closes

(spill)

rpm rpm

45°

30°

inches

BTDC

kg/cm') kg/cm')

(44AlFour) (44B/Four)

(0.0098

-0

psi

(140

384

I

ntake

Intake 17° 45° 3600

3000

Intake

Exhaust

0.25

1991 + 71

17°

overhead

(1.758

liter)

from

(472.4

mm)

transmission.

3600

to

exceed

at

280

mm)

+ 5 - 0

fresh

valve

mm)

the

mm)

rpm

30

rpm

kgf/cm').

water-

front.

min.)

General

Fuel Fuel

Injection Nozzle Fuel

Filter

Air

cleaner

AirAow (engine

combustion)

Fuel

Lift

Pump

General

Operating

discharge elbow)

System

General

Temperature

Fresh

Water

Raw

Water

Raw

Water

(measured

(Fresh

Oil Sump

(not Operating

(engine Oil

into

Approximate

Capacity

Water)

Filter

Capacity

including

Oil

hot)

Grade

Pump

COOLING

Pump

Flow before

exhaust

LUBRICATION

filter)

Pressure

FUEL

SYSTEM

Open

flow,

No.2

diesel

In-line

plunger

Throttle

type.

Spin-on

replaceable. Replaceable 140

cfm

(3.9

93

cfm

(26.2

12

volt

DC

Fresh

water-cooled

controlled 170

-190° F Centrifugal Positive

displacement,

belt-driven.

44AJFour 44B/Four

·8.0

US

qts

Pressure

fed

Full

flow,

paper

5.2

U.S.

qts

50 -60

psi

API

Specification

SAE

30,

10W-30,

self

priming.

oil

(cetane

rating

type

(BOSCH).

paper

filter

cartridge.

cmm)

at

3600

cmm)

at

3000

lift

capacity

of

SYSTEM

block,

with

heat

exchanger.

(77 -88°

type,

(7.6

metal

9.5

8.0

liters)

C) impeller, rubber

gpm gpm

SYSTEM

system.

element,

(5.4

liters)

(3.5 -4.2

kg/cm')

CF

or

CG-4,

15W-40

of

45

or

higher).

rpm. rpm.

5'

(1.5

mm)

solid

thermostatically-

belt-driven.

impeller,

at

3600

rpm

at

3000

rpm

spin-on

type.

state

ELECTRICAL

Starting

Battery

Capacity

Battery DC

Charging

Alternator

Starting

Aid

Starter

12 400 -600 51 Glow

12

Volt,

Amp

plugs,

Volt,

SYSTEM

(-)

negative

Cold

Cranking

rated,

belt-driven

sheathed

reduction

ground

type

gear

Amps

(CCA)

Engines & Generators

51

Rev.

July

2002

35C

&

350

THREE

ENGINE

SPECIFICATIONS

Engine

Type

Displacement Aspiration Combustion Bore & Stroke Rring Direction Compression Dimensions -inches

Engine

Weight Inclination

Order

of

Only

Chamber

Rotation

Ratio

TUNE-UP

Compression Minimum

Valve

Spilled Valve Engine

Injector

Valve

(engine Engine

Pressure

liming

(Static)

Seat

Angle

liming

Pressure

Seat

Angle

Clearance

cold)

Speed

SPECIFICATIONS

Diesel,

(mm)

four-cycle,

cooled,

vertical

mechanism

80.4

cubic Naturally Swirl

type.

3.07 x 3.62

1 - 3 - 2

Clockwise, 22:1

Height:

Width:

Length:

276

Ibs

(276

Continuous

Temporary

three-cylinder,

in-line

..

inches

(1.318

aspirated.

inches

when

viewed

21.6

inches

20.1

inches

22.4inches kgs)

without

15·

25·

(not

SPECIFICATIONS

427

psi

(30

psi

(27

Opens Closes

(spill)

BTDC

45·

30·

inches

rpm rpm

kg/cm') kg/cm')

-0

psi

(140

(0.25

(35ClThree) (35DlThree)

384

Intake Intake

17· 45· 17· 1991 + 71 Intake

Exhaust

0.0098

3600 3000

overhead

liter)

(78 x 92

from

to

exceed

at

280

+ 5 -0

mm)

fresh

water-

valve

mm)

the

front.

(540.6

mm)

(510.5

mm)

(596

mm)

transmission.

30

min.)

rpm

kgf/cm').

General Fuel Fuel

Injection Nozzle Fuel

Riter Air

cleaner

AirFlow

(engine

combustion)

Fuel

Lift

Pump

General

Operating Fresh Raw

Raw (measured discharge elbow)

System (Fresh

General Oil Sump

(not Operating

(engine Oil

Temperature

Water

into

Approximate

Capacity

Water)

Riter

Capacity

including

Oil

hot)

Grade

Pump

COOLING

Pump

Row

before

exhaust

LUBRICATION

filter)

Pressure

FUEL

SYSTEM

Open

flow,

No.2

diesel

In-line

plunger

Throttle

type.

Spin-on

replaceable

Replaceable

83.7

cfm

(2.3

69.7

cfm

(1.9

12

volt

DC

Fresh

water-cooled

controlled 170

-190· F Centrifugal Positive

displacement,

belt-driven.

35C/Three 35D/Three

5.0

US

qts

Pressure

fed

Full

flow,

paper

3.9

U.S.

qts

50 -60

psi

API

Specification

self

priming.

oil

(cetane

rating

type

(BOSCH).

paper

filter

cartridge.

cmm)

at

3600

cmm)

at

3000

lift

capacity

of

SYSTEM

block,

with

heat

exchanger.

(n

-88·

C)

type,

metal

impeller, rubber

9.5

gpm

8.0

gpm

(4.7

liters)

SYSTEM

system.

element,

(3.7

liters)

(3.5 -4.2

CF

kg/cm')

or

CG-4,

of

45

or

higher).

rpm. rpm.

5'

(1.5

mm)

solid

thermostatically-

belt-driven.

impeller,

at

3600

rpm

at

3000

rpm

spin-on

type.

state

ELECTRICAL

12

Starting

Battery

Capacity

DC

Charging

Altemator

Starting

Aid

Starter

Volt, 400 -600 51

Amp Glow 12

Volt,

(-)

negative

Cold

rated,

plugs,

reduction

sheathed

SYSTEM

Cranking

belt-driven

gear

ground

Amps

type

(CCA)

Engines & Generators

52

Rev.

July

2002

44

FOUR

AND

35

THREE

TORQUE

SPECIFICATIONS

Bolt

or Nut Diameter Pitch across flats

Alternator

Back Connecting Coolant Coolant Coolant Coolant Crankshaft Cylinder Damper Delivery Engine Exhaust Flywheel Fuel Fuel Fuel Fuel Fuel Glow Glow Intake Main Oil Oil Oil Oil Oil Pressure Rear Rear Retaining

Valve Rocker

Rocker Sliding Special

Torque

Starter B Terminal

Stop Thermostat Thermoswitch

Bracket

Plate

Rod Pump Pump

Temperature Temperature

Pulley

Head Plate Valve

Mounts

Manifold

Bolt

Filter

Assembly Injection Injection Leak-Off Solenoid

Plug Plug

Connection

Manifold

Bearing Filter Pan

Bolt

Pan

Drain Pressure Pressure

Refief

Plate

Bolt

Plate

Bolt

Nut

Holder

Cover

Shaft

Sleeve

Nut

Spring

Solenoid

Cap

Pulley

Bolt

Holder

Nozzle Pipe

Pipe

Locknut

Cap

Plug Sender Switch

Valve (stamping) (standard)

for

Body

Bolt

Bracket

Shaft

for

Set

Housing

Sender Switch

Nut

Holder

Nut

Plate

Bolt

Delivery

Bolt

M9

M18 M10

M12

M20 M12 M12

M10 M4

M10 M20 M8 M14

PT1/8

M22 M8 M12 M16

M8 M8 M10 M12

M8 M30

M16

MAJOR

BOLTS

1.0

1.5

1.25

1.5

1.25

0.7

1.25

1.5

1.25

1.5

1.25

0.75

1.25

1.0

1.25

1.5

AND

NUTS

Width

14

27 14

19

21

18

12 8

17

12 22

26 22

12 16 17 19

12 12 14 17

12 36

17

Clamp

length

87

29

60

81

25 10

11 33

28

40 581

29.5

31.5

TORQUE

kg -m

3.8-5.3

3.3-4.8

3.55±0.25

1.6±2.4

1.6 ± 2.4

1.2±1.8

17.5±2.5 127±18 9±0.5

1.9±

2.7

4.5±0.5

3.2±4.7

1.6±2.4

13.5±0.5 98±4

4.6±6.8

5.5±0.5 3±0.5 22±4 29±5

2.75±0.25

4.0±0.5

1.75±0.25

0.125 ± 0.025

1.6±2.4

5.25 ± 0.25

1.2±0.1

2.8±0.3 20.3±2.2 27±5.3

4.0±

0.5

1.2±1.8 1 ±0.2 7.2±1.4 10±2

5.0±0.5

1.15

±0.15

6.5

±0.1

3.75 ± 0.25

1.15±0.15

1.5±0.5

3.6±0.6 26±4 2±0.5

1.1

±0.1

4.5±0.5

0.3-0.45

2.3±0.4

ft - Ib

27-38 24-35 27±72 12-17 12-17 9-13 9-13

65

± 4 88± 5 14-20 32±54 23-34 12-17

33-49 40±44

20± 2

28.9±36.2 12±72

0.9 ± 0.2 12-17 38±2 51.5±2.5

8.7±

29±4 39±5 9-13

36±4 49±5

8.3±1.1

47±7 64±10

27±2 37±2.5

8.3±1.1 11

±4

14±4 80±7

32±54

2-3

16.6

± 3

0.7

N-m

36.6

32.5

34.8±2.5

17.2

12.2

172±25

8.9

44± 5

31.1

7.2 132±5

44.7 54±5

27±2.5

39.18

17.2±2.5

1.2±0.2

16.2

12±1

12.2

11.3

±1.5

11.3±1.5

14.7

± 5 35±6 20±5

10.8±1 44±5

2.7

22.6

± 4

Engines & Generators

53

BOLT

HEAD

Bolt

strength

Customary (strongest), Le,; a grade

MARKINGS

classes

are

(inch)

bolts

are

The

marks

seven

correspond

bolt

will

embossed

identifed'

display

five

on

the

by

markings

to

two

embossed

head

marks

STANDARD

of

each

bolt.

two

to

grade

eight

less

than

the

actual

marks.

grade,

HARDWARE

Metric

bolt

class

numbers

strongest.

identify

bolts

by

their

strength

with

10.9

the

NOTES:

1.

2.

3.

Use These Reduce

STANDARD

Capsrew

Body

1/4·

20

·28

5/16-18

-

24

318-16

-

24

7/16-14

-

20

1/2

-13

-

20

9/16

-12

-18

5/8-11

-18

314

-10

-16

7/8

- 9

-14

1 - 8

-14

Size

(Inches) • (Thread)

the

torque

values

listed

below

when

specific

torques

are

based

on

clean,

dry

threads.

torques

by

30%

or

more,

when

threading

BOLT & NUT

SAE

Grade

Torque Torque Torque

A·Lb(Nm)

8

10 17

19

31 35

49 55

75

85

110 120

150 170

270 295

395 435

590 660

5

.

(11) (14)

(23) (26)

(42) (47)

(66) (75)

(102) (115)

(149) (163)

(203) (231)

(366) (400)

(536) (590)

(800) (895)

TORQUE

SPECIFICATIONS

SAE

Grade

6·7

FHb(Nm) FHb(Nm)

10

(14)

19

(26)

34

(46)

55

(75)

85

(115)

120

(163)

167

(226)

280

(380)

440

(597)

660

(895)

SAE

12 14

24 27

44 49

70 78

105 120

155 170

210

240

375 420

605 675

910 990

Reduce

Grade

torque

values

torque

capscrews

8

(16) (19)

(33) (37)

(60) (66)

(95) (106)

(142) (163)

(210) (231)

(285) (325)

(508) (569)

(820) (915)

(1234) (1342)

are

not

by

10%

into

aluminum.

METRIC

Boll

Dia.

M3 M4 M5

M8 M9

Ml0

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

available.

when

Wrench

Size

5.5mm 7mm 8mm

10mm 13mm 16mm

18mm 21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

engine

oil

istJsed.

BOLT & NUT

Grade

4.6

A'Lb(Nm)

0.3

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

TORQUE

Grade

FHb(Nm)

0.5

85

118 166 225

288 417 568

774 992

SPECIFICATIONS

4.8

(0.7)

1

(1.5)

2

(3)

4

(5.5)

10

(13)

18

(25)

33

(45)

55

(75)

(115)

(160) (225) (305)

(390) (565) (770)

(1050) (1345)

Grade

8.8 • 9.8

FI·Lb(Nm)

1

(1.3)

2

(3)

4.5

(6)

7.5

(10)

18

(25)

37

(50)

63

(85)

103

(140)

159

(215)

225

(305)

321

(435)

435

(590)

553

(750)

811

(1100)

1103

(1495)

1500

(2035)

1925

(2610)

Grade

FI·Lb

1.5 3

(4.5)

6.5

11

(15)

35

(26)

55

(75)

97

(130)

151

(205)

232

(315)

321

(435)

457

(620)

620

(840)

789

(1070)

1154

(1565)

1571

(2130)

2139

(2900)

2744

(3720)

10.9

(Nm)

(2) (9)

NOTE:

Formula

to

convert

Ft-Lbs

to

Nm

GASKETSISEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper

ing

assembly.

Specialized

ing copper

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

sealers

properties.

gaskets

and

it's

HIGH

effective

fuel.

LIQUID

TEFLON

should

oil

pan

gasket

seal

around

grease.

SPRAYS

such

as

HYLOMAR

as

it

TACK

in

just

about

can

be

used

with

water

are

useful

HYLOMAR

is

resists

fuel,

equivalent

any

be

used

on

high

(coolant)

for

holding

work

particlarly

oil

(Newton

Meters)

multiply

Ft-Lbs

by

1.356.

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

joint

oil

adapter

temp

well

and

are

excellent

in

contact

on

rubber

hoses

RED

SILICONE

passages,

gaskets

in

applications

effective

water.

all

with

gaskets

and

the

oil

sealer.

coat

both

in

position

dur-

requir-

on

Engines. & Generators

passages.

Do

not

BOLTS & FASTENERS/ASSEMBLIES

Lightly

oil

head

plugs

that

penetrate

HIGH

TACK.

When

assembling

Anti-seize threaded LOCTITE

LITHIUM ing

Heavily use

compounds

components

offers

based

boxes.

oil

all

clean

engine

sliding

use

bolts

and

the

levels

grease

and

oil!

sealing

tape

sealants!

other

water

flywheel,

and

thread

yet

allows

of

locking

is

waterproof,

reciprocating

54

pipe

plugs

fasteners

jacket

should

coat

the

locking

them

according

ideal

and

fillings

as

you

assemble

be

sealed

bolt

threads

adhesives

to

came

apart

to

the

job.

for

water

components

that

with

LOCTITE

such

as

when

pump

when

assembling.

connect

coolant

them.

Bolts

and

PERMATEX

blue.

LOCTITE

protect

necessary.

bearings

and

Always

#2

or

stuff-

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

(in3) 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

qt) x .946 = Liters

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

In

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

gal) x 3.785 = Liters

(g) x .035 = Ounces

(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

qt) x .833 = IMP

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

=i

n

pt

qt

gal

qt

gal) x .833 = IMP

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

Fahrenheit

Celsius

(0C)

(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

=

(OF -32) x .56

Engines & Generators

MPG

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

Hour

(KPH) x .621 = MPH

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

55

SUGGESTED

WESTERBEKE

SPARE

MARINE

PARTS

DIESEL

ENGINES

CONTACT

RAW

WATER

IMPELLER/GASKET

YOUR

PUMP

"","-.",,'~!"'"

WESTERBEKE

DEALER

FOR

SUGGESTIONS

AND

ADDITIONAL

INFORMATION

HARDWARE

KIT

FUEL

LIFT

PUMP

WESTERBEKE also offers two Spare Parts Kits, each packaged in a rugged hinged toolbox.

Kit

"A"

includes the basic spares.

Kit

"B"

is for more extensive off-shore cruising.

A

Kit

Impeller Kit Heat Exchanger Gasket Fuel Filter with Gasket Oil Filter Drive Belt Zinc Anodes

WESTERBEKE ENGINE

AND A GALLON

RECOMMENDS

OIL

(YOUR

SPARE

I

"'fIV'/WESTERBEKE

I

BRAND)

OF

PREMIXED

EnaitJes

~~

FOR

PARTS

& Generators

WATER

CARRYING

AN

OIL

COOLANT.

KITS

56'

SEPERATOR

ENOUGH

CHANGE

(5

SPARE

OTS.)

AIR

INTAKE

FILTER

B

Kit

Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Injector Fuel Filter with Gasket Oil Filter Drive Belt

FILTER

EUROPEAN

MARITIME

COUNCIL

REGISTRATION

EUROPEAN ECONOMIC

COUNCIL

Declaration of Conformity

Application

of

Council Directives

Standard(s) to Which Conformity is declared

and

Manufacturer's Name

of

Type

Equipment

Address

Product Name ModeI(s) Product

Options

Supplementary Information

1.) The equipment listed

is

only for use in Marine Applications aboard boats.

2.) The equipment listed must be located below decks on the vessel and permanently installed in it's location.

3.) The equipment listed must be wired to the grounding system of the vessel. that

I the undersigned, hereby declare

the equipment specified above conforms to the above Directive(s) and

Standard(s).

Place Taunton Massachusetts. U.S.A

EMC

89/336IEEC

9

EN50081-1 EN50082-2 EN55020

Westerbeke Corporation 150

John Myles Standish Industrial Taunton, MA 02780,

Hancock Road

Park

USA Marine Diesel Engine Westerbeke Marine Diesel Engine 44A-Four I 35C-Three

All

/?

~

_

~

(Signature)

/

\/-

Date April

INTERNATIONAL

I

MANUFACTURER

I

ADDRESS MODEL

SPECIFICATIONS Engine Fuel Aspiration

Rating Crankshaft Power Propeller shaft at

RPM

CertHication

Signed Name

Title

EU

NotHied

Date

Power

Company: Date:. Name: Title: Signature:

Rond

Type

Tvpe

Level

NAME

Type

Body

rating

3.

Point

We

Power

Number

No

is

2000

Schuman

in

inboard

6,

Box

6'

hereby certify that

I I

(kW) (kW) (min")

accordance

petrol

en

with

ines).

Carleton

MARINE CERTIFICATION

B •

1040

BRUXELLES

• BELGIQUE'

tel:

+32

(0)

2-238-7892 • fax:

CERTiFiCATE

the

engines(s)

1999I.M.C.1. Power

150

Highest

3.600

Manufacturer's

IMCI

Proceedure.

This

application

John

Output 27 27

stated below

Hancock

1

verHication

Compliance

form

meet

the

EC

Rating

Report

Westerbeke

Road

Myles

Standish

2 3 4

·

Directive 94/25/EC.

Corporation Industrial

44A-Four

Inboard

Diesel

Natural

· ·

· · · ·

WESTEBIDOOh

,~

-"7_

E.

Granholm

Director

0609

3-April-2000

with

Corporation

3-April-2000

Carl

F.

Brvant

/7.

C/

..-'

J.r?~

with

any other

~

has

t-/

verHied

not

been

/I

I/,

Lars

Manaaina

statement

in

accordance

lodaed

Westerbeke

Chief Operating Officer

v

F.

Bryant. Chief Operating Officer

INSTITUTE

+32

(0)

2-238-noo

Park

Taunton

MA

02780

USA

Lowest

Output 5

·

.;-

ISO

8665

and

ISO

15584

(only

not

Hied

body.

for

I

Engines & Generators

57

EUROPEAN

MARITIME

COUNCIL

REGISTRATION

INTERNATIONAL

Rond

Point

Schuman

I

MANUFACTURER ADDRESS

I

MODEL SPECIFICATIONS

EnaineType Fuel Aspiration

Ratina Crankshaft Power Propeller shaft Power at

litle

Type

Level

RPM

CertHication Signed Name

EU

Not

Date

Power

Company: Date: Name: litle: Signature:

NAME

Type

Hied

Number

Body

rating

We

No

is

in

inboard

~

EUROPEAN ECONOMIC

MARINE CERTIFICATION

6 - B - t040

BRUXELLES -BELGIQUE

CERTKFKCATE

the

,

with

en

I I

I

IMCI

lines).

engines(s)

19991.M.C.1.

150

Hiahest

3.600

This

application

John

Output 21 20

stated

Power

Hancock

1

;

form

Road

verHication

has

hereby

jkW)

petrol

6,

Box

certify that

(kW) (min")

COUNCIL

-tel:

+32

{OJ

2-238-7892 -fax:

below

meet

the

EC

Rating

Report

Westerbeke

Myles

Standish

jgL

· · · ·

·

Directive

Corporation Industrial

3SC-Three

Inboard

Diesel

Natural

(3)

J4)

· ·

INSTITUTE

+32

94/25/EC.

Park

Taunton

Lowest

· · ·

I

verHied

not

/7

/./

WESTERIDO..Q.4

I

'-r.,/U

Lars

Managing

statement

in

been

lodged

Carl

•

Chief

'-;1YYA.

.!::.

~,

."

7-

E.

Granholm

Director

0609

3-April-2000

I

wijh

with

any

other

F.

Bryant

Operatina Officer

or

.'-.

ISO

8665

notHied

and

body.

(OJ

2-238-7700

MA

Output{S)

·

ISO

15584

~

02780

USA

(only

I

for

Engines & Generators

58

Engines & Generators

Westerbeke 44bB-35 D THREE, 44A FOUR, 35C THREE, 448 FOUR, 35D THREE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual