Westerbeke 55B-FOUR, 55C-FOUR, 55D- FOUR Operator's Manual

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. PUBLICATION NO.42286

REVISION 4

JULY

2011

.. - - ,

WESTERBEKE

. WESTERBEKECORPORATION.150JOHNHANCOCKROAD

MYLES

STANDISH

WEBSITE:

INDUSTRIAL

www.WESTERBEKECOM

PARK·

TAUNTON

MA

·'''''i.

02780

0-

CALIFORNIA

PROPOSITION

WARNING

Exhaust gasoline its the cancer, reproductive

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea.

-Headache

-

Weakness

IF

YOU GET seek until

gas

engines

constituents)

State

of

birth

gasses

gas.

Carbon

can

include:

andSleepiness

OR

ANYONE

OUT

INTO

THE

medical

It

has

attention.

been

from

California

defects,

harm.

contain

and

inspected

65

diesel

and

(and

some

of

are

known

to

cause

and

other

A

WARNING:

Carbon

Monoxide,

Monoxide

death.

ELSE

EXPERIENCE

FRESH

Shut

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability ANY

AIR

IMMEDIATELY. down

the

and

repaired.

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

odorless

and

Temples

THESE

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

persist,

A

WARNING

should

be

fixed

generator.

WESTERBEKE

MONOXIDE

of

your

obtainable

DETECTORS

vessel.

at

DECAL

is

to

a

also

recommends

They

your

local

provided

bulkhead

in

the

are

inexpensive

marine

Engines & Generators

by

WESTERBEKE

near

your

engine

installing

living/sleeping

store.

and

easily

CARBON

and

or

quarters

WARNING

Gooem\ors

PIrXIuce

CARBON

Regular

~

MailIenance

MClNOXIDE

ReqoJrecI

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure

to

fol1ow

tions.

Know

when

dangerous necessary and your The the

PREVENT

A

while

power.

•

• Electrical shock results

PREVENT

A

exhaust

very

•

A

• In

precautions

to

machinery.

following

American

WARNING:

Do enclosures

Shut equipment.

Use equipment.

Make (particularly

Remove electrical

Do circuits, except through a transfer result

tor.

safety

instructions

Boat

and

ELECTRIC

Do

not

engine

is

running,

Lethal

voltage

not

operate

off electrical power

insulated

sure

not

connect

if

Discharge

this

and

covers

mats

your

clothing

shoes)

wristwatch

equipment.

utility

switch.

Damage

this

procedure

capacitor

machinery

whenever

when

Yacht

SHOCK

is

and

BURNS -HOT

WARNING:

system

hot!

Always

recovery

WARNING:

case

before

touching the engine

Do

not

components. A running

check

the

engine

tank.

Steam

of

an

engine

carefully.

fundamental

conditions

protect

yourself,

are

Council

touch

AC

Dr

when

present

in

place.

before

working

and

skin

handling

all

jewelry

shore

power

ship-to-shore

to

vessel's

is

not

followed.

from

handling

by

shorting

ENGINE

touch

hot

coolant

can

cause

overheat,

or

Most

accidents

rules

exist and

your

in

compliance

(ABYC)

electrical connected

at

these

connections!

without

electrical

accessing

on

are

dry, not

electrical

when

to

vessel's

double

AC

generator

a charged

terminals

engine

electrical

parts

engine

level at the

injury

Dr

allow

the

engine

checking the

are

and

precautake

the

personnel,

with

standards.

connections

to

shore

electrical

damp

equipment.

working

on

AC

throw

may

capaci-

together.

Dr

gets

coolant

death!

to

cool

coolant.

PREVENT

A

• Prevent sparks pump, vapors. removing

•

Do arrester

death.

•

Do Backfire

•

Do the engine/generator chances

•

Be

PREVENT

A

injury

•

Follow hatches after

•

• Do

•

• Be certain fuelliue

•

BURNS -FIRE

WARNING:

to or

Use a suitable

not

operate

not

operate

not

smoke

fuel

aware -diesel

Fire

flash

fires.

Do

occur

near

other potential

the

fuel

line,

with

removed.

can

system.

of

cause

fire.

Backfire

with

or

permit

Keep

clean

Wipe

severe

can

not

the

container to catch

a Coast

the air cleaner/silencer removed.

the

up

fuel

BURNS -EXPLOSION

WARNING:

Dr

death!

fueling.

ning

the

starting your All

fuel

when

handling tilated area away out of the reach of

Do

not

Shut

off

the

fuel

spill.

DO

sources

ing.

Ensure proper ventilation exists

fuel

system.

not

Be

sure

free

ofleaks.

Make

sure a properly maintained. Be fantiliar Extinguishers

all

applications encountered in

for

Explosions

re-fueliug

closed

when

Check

blower.

engine.

vapors

are

and

fill the

fuel

the

fuel

system.

NOT

of

fire

near

alter or

all

modify

fuel

fire

rated

safety

fueling.

below for fumes/vapor before

Run

the blower for

highly

storing

from

children.

tank(s)

service

Take

care in catching

allow

any

the

supplies

fittings

extinguisher

ABC

cause

injury

Dr

death!

smoke

or permit flames or

carburetor,

sources

carburetor,

can

injury or

flames

compartment and the

and free of

all

will

from

instructions.

explosive.

fuels.

spark-producing equipment

while

valve

smoking,

fuel

system

the

have a positive shutoff

by

of

Guard

cause

or

spilled

bum.

fuel

Open

at

fuel

system.

are

adequately

is

the

installed

or

sparks

debris

Store

the engine is

or

with

NFPA

fuel

line, filter,

spilled

fuel

or

all

fuel when

fuel

filters.

Approved flame

severe

injury

death.

to

occur

to minllnize

fuel

and

engine

vapors

can

Keep

the vessel's

and

ventilate cabin

four

minutes

Use

extreme

fuel

in a

well-ven-

running.

engine

when

any

fuel that

open

flames,

engine

when

servicing

valve.

tightened

nearby

its proper

are

appropriate

this

environment.

fuel

or

near

the

oil.

cause

run-

before

care

and

servicing

might

or

other

servic-

the

and

is

use.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

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

• Make certain starting.

• Make certain installed before starting the engine.

BAnERY

A

WARNING:

or

death!

• Do not smoke or allow an 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 equipment in ing servicing.

• Never connect the negative (-) battery cable

tive not test the battery condition together. Ventilate any compartment containing batteries

accmnulation of explosive gases. disturb the battery charger connections while the battery is

being charged.

•

Avoid bums or sparks that could cause wristwatch, rings, and the battery.

• Always tum the battery charger off before disconnecting the battery connections. Remove the negative lead first

and reconnect

STARTING

Accidental

all

personnel

all

covers,

starting

are

guards,

can

clear

of

the engine before

and hatches

cause

are

EXPLOSION

Batteryexplosion

the

vicinity

(+)

connection terminal of the starter solenoid.

Sparks could ignite battery gases or fuel vapors.

contacting the terminals with tools, etc.,

it

last when disconnecting the

to

any

can

cause

injury

open

flame near the battery

all

electrical

prevent electrical

by

shorting the terminals

To

avoid sparks,

an

explosion. Remove

other jewelry before handling

arcing

to

battery.

injury

the

engine!

re-

the

posi-

Do

to

prevent

do

to

prevent

dur-

not

BAnERYACID

TOXIC

• Ensure that

• Be sure the unit

EXHAUST

A

WARNING:

discharged from regularly for are

securely attached and no warping exists. attention exhaust pipe

• In addition install a carbon monoxide detector. Consult your boat builder or dealer

• For additional information refer tional information

A

WARNING:

odorless nausea

•

• Do not install exhaust outlet where exhaust can be

• Although diesel engine exhaust gases

AVOID

gas.

or

Do

not use copper tubing in diesel exhaust systems.

fumes

can

tems.

Exhaust

tubing resulting

through portholes, vents, or air conditioners. exhaust discharge outlet enter the exhaust flow

of

exhaust.

exhaust fumes gas

is present in diesel exhaust

toms

or

are:

Vomiting Dizziness Intense headache Throbbing in

MOVING

GASES

Carlion

monoxide

the

exhaust

leaks

to

the manifold, water injection elbow, and

nipple.

to

routine inspection of the exhaust system,

Inhalation

system

the

engine. Check the exhaust system

and

make sure the exhaust manifolds

and

its surroundings

for

installation of approved detectors.

on

Carbon Monoxide).

Carbon

monoxide produces

(CO)

is

adequate

to

ABYC

(CO)

flu-like

is a deadly

to

expel gases

Pay

are

well ventilated.

T-22 (educa-

is

an

inviSible

symptoms,

death!

rapidly

destroy copper

sulfur

causes rapid deterioration of copper

in

exhauslfwater leakage.

is

discharge

Avoid

overloading the craft.

from

gasoline engines, carbon monoxide

signs of carbon monoxide inhalation or poisoning

Muscular twitching

temples

Weakness

tubing

in

exhaust

If

near the waterline, water

outlet

and

close

or

restrict the

are

not as toxic

fumes.

Some

of

and

sleepiness

PARTS

gas!

close

the

Diesel

sys-

drawn engine

could

as

symp-

A

WARNING:

severe

injury

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and tion.

Batteries contain sulfuric acid which

If

it comes in contact with your skin, wash

with

water.

inadvertently when removing electrolyte caps.

Sulfuric

or

death!

Acid may splash

acid

in

batteries

on

the skin or into

can

cause

eye

is

destructive.

it

off at once

the

protec-

eyes

Engines &

A

WARNING:

or

death!

•

Do

not service

tion

arises operating adjustments, ing

moving parts

Generators

ii

Rotating

the

in

which

parts

can

cause

injury

engine while

it is absolutely necessary

use

and

hot exhaust system components.

it

is

running.

extreme care to

avoid

If

to

a

situa-

make

touch-

•

Do

not wear loose equipment; jackets, could be caught

•

Make

Keep

places

•

Do

not check

tlte

engine

•

Stay when

be caught in

HAZARDOUS

A

WARNING:

tie

shirts,

sure

all

protective

at

all

times.

is

clear of

tlte

engine

NOISE

attaching

fluid

operating. tlte

tltese

loss!

• Never operate

•

Do

not

run

an

removed.

•

Do

not

run

engines

open.

A

WARNING:

mentally

or

physically

clothing

back

long

sleeves,

an

engine

in

moving

shields

levels

drive is

running;

rotating

High

engine

for

00

not

rings,

shaft

noise

witlt

long

work

incapacitated

or jewelry

hair

and

necklaces

parts.

hardware and

guards

or

tlte

and

hair

parts.

levels

witltout

tlte

air intake

periods

on

SAFETY

when

avoid

wearing

or

bracelets

is

properly

in

tlteir

respective

drive

belt's tension

tlte

transmission

and

clothing

can

cause

its

muffler

(silencer)

witlt

tlteir

machinery

by

fatigue!

when

servicing

loose

tltat

tightened.

while

coupling

can

easily

hearing

installed.

enclosures

you

INSTRUCTIONS

ABYC,

INSTALLING

Read for tions

ABYC

"Safety Order

NFPA

"Fire Order

USCG

"USCG Order

are

NFPA

AND

DIESEL

tlte

following

safety

codes

and

when

installing

(American Standards

from:

ABYC 3069

Solomon's Island

Edgewater,

Protection

from:

NFPA 11

Tracy Avon Avon,

from:

U.S. Washington,

MD

(National

Industrial Park

(United

33CFR183"

Government Printing

Fire Protection

Standard for Motor

Drive

MA

02322

States

D.C.

USCG

ABYC,

standards.

your

Boat

for

21037

PUBLICATIONS

ENGINES

NFPA

and

Follow

engine.

and

Yacht

Council)

Small Craft"

Rd.

Association)

Craft"

Coast

Guard)

Office

20404

USCG

publications

tlteir

recommenda-

FOR

OPERATORS

Many

of

in

your

notes

to carefully, procedures.

GASOLINE

Preparations begin

witlt

Yacht

Council's

a combination of Sections H-2

Ventilation

H-24

Gasoliue

P-l Exhaust

P-4

Inboard

E-9

DC

All

installations

Regulations

MANUAL

tlte

preceding

Operators

highlight critical

maintain

Manual

ENGINE

to

install

a tltorough exantiuation of tlte

(ABYC)

sources

of

tlte

ABYC

Fuel

Systems

Engines

Electrical

must

(FCR).

safety

tips

and

warnings

along

witlt

otlter

cautions

information.

your

equipment,

AND

GENERATOR

a gasoline engine or generator

standards. including

standards

Systems

comply

witlt

Read

and

follow

INSTALLATIONS

American

These

standards

1he

USCG

of particular interest

tlte

Federal Code of

your

and

are

manual

all

safety

tlte

repeated

and

should

Boat

and

are

from

NFPA.

are:

".

WESTERBEKE

Engines & Generators

iii

When

installing

attention

WESTERBEKE

be

paid

to

the

following

INSTALLATION

engines

information:

and

generators

it

is

important

that

strict

CODES

Strict

when

AND

federal

regulations,

installing

REGULATIONS

ABYC

engines

and

SIPHON·BREAK

For installations or

will

be

break

in

the

minimum

the

exhaust manifold injection port

raw

water

If

you

have

to

the

vessel's waterline under

siphon-break.

NOTE:

A

siphon-break

operation.

engine

damage.

EXHAUST

The

exhaust hose must be prevent water of the

vessels

where

below

the

raw

water supply

of

20"

above

damage

Failure

any

to

doubt

to

Consult

SYSTEM

from hull.

the

vessel's

the

the engine

about

requires

properly

the

entering

guidelines,

generators

exhaust

manifold/water injected exhaust

waterline,

hose

to

vessel's

waterline.

is

and

the

position

the

vessel's valious operating conditions, install a

periodic

maintain a siphon-break

Siphon-break

certified

the

for

exhaust

and

safety

in a marine

provisions

the exhaust

at

or

possible flooding

of

inspection

manufacturer

maline

under

environment.

must

elbow.

Failure

belbw

the

water-injected exhaust

and cleaning

use.

The

any

sea

codes must

be made

This hose

to

use a siphon-break when

Ibad

waterline

of

the

boat.

can

result

for proper

system must

conditions

be

complied

elbow

is

to

install a siphon-

must

be

will

result

elbow

to

ensure

proper

in

catastrophic

maintenance.

be

desigued

and

at

any

with

close

to

looped a

in

relative

to

angle

A

detailed engines to

download

Marine

and

generators,

from

Installation

is

supplied

our

website

-."y:

WESTERBEKE

Engines & Generators

Manual at

covering

with

each

gaSOline

unit. A pdf

www.westerbeke.com.

iv

and

diesel,

is

available

TABLE

OF

CONTENTS

Parts

Identification

Introduction

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

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

Siphon Break .................................................... 4

Admiral

Captain Fuel,

Engine

Preparations

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

Control Control

Oil

for Starting/Stopping Warning Engine The

Lights,

Break-In

Daily

Operation

Maintenance Fuel

System

FuellWater Separator ......................................

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

COOling

Changing Coolant ........................................... 16

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

Raw Water Intake Strainer .............................. 17

Raw Water Cooling Circuit ............................

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

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

Zinc Anode ..................................................... 19

Air

Intake/Silencer .......................................... 19

Engine

Changing the

Changing the Oil ............................................ 20

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

System

Lubricating

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

Panel

..........

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

Panel

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

and

Coolant..

Initial

Start-Up

Procedure

Alarms

Procedure

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

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

.....

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

and

Circuit

Breaker

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

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

Schedule

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

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

System

Oil Filter ................................... 20

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

....

2

3

5

6

7

8

9

10

11

.12 .13

15 15 15

16

17

18 18

18

20

Remote Water

Tachometer DC

Glow

Wiring

Wiring Starter Dual

Engine Engine

Hurth

Borg

Lay-up Metric Engine Suggested

Oil

Filter

Heater

(Optional)

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

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

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

Electrical

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

Battery Care .................................................... 25

Plugs

Diagram Schematic

Output

Troubleshooting ..............................................

Troubleshooting

Adjustments

Belt Adjustments ........................................... .35

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

Testing Engine Compression .......................... 36

Oil Pressure ....... : ............................................ 36

Valve Clearance Adjustment .......................... 37

HSW

Transmission Coolers ...................................

Maintenance ................................................... .40

Troubleshooting ............................................. .41

Warner

Maintenance .................................................... 45

Oil Coolers ...................................................... 45

System

......... ~ .................................

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

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

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

Motor

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

Alternators ....................................

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

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

Transmissions

Transmission

and

Recommissioning

Conversions

Specifications

Spare

Parts

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

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

Oata

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

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

21 22

.23

24

26

27

28 29

31

32

.33

.35

.3

.40

43

.46

48

.49

50

8

Engines & Generators

1

PARTS

IDENTIFICATION

RAW

WATER

FRONT

om,,"

THERMOSTAT ASSEMBLY

___

DC

PREHEAT

~Ul.<Nl"U,

Oil

FIll

AlTERNA1'OR

(

WATER

EXHAUST

"'"'~~

INJECTED

PUUILAW

I

PRESSURE

CAP

LEFT

INTAKE/AIR

I.D.

~_'r--lltAI

SIDE

FILTER

WATER

INJECTED

EXHAUST

PLATE

EXCHANGER

ANDDE

ELBOW

REAR

HEAT

EXCHANGER

AIR

.

FUEL

LIFT

FUEL

FILTER

-------;>

SHIFT

LEVER

INTAKE/AIR

PUMP

20A

CIRCUIT

BREAKER

----:-~~

RIGHT

SIDE

OIL

COOLER

OIL

PRESSUIRE

SENDOR

MOUNT

FIll

THERMOSTAT

___

,.,,,,,n

CONNECTION

~--U"

CRANKSHAFT PULLEY

HEATER

ALTERNATOR

FRONT'

Oil

FIll

Engines &

2

Generators

This

WESTERBEKE WESTERBEKE's technology.

dependable

Thank

In

order important that manual ual

carefully out. nearest

This provided WESTERBEKE equipment, WESTERBEKE'S installation

We performance of

you

for

to

get

is

designed

and

Should

your

WESTERBEKE

is

your operators

and a technical

contact

WARRANTY

Your

WESTERBEKE

folder.

If, after

form

you

have

registering

writing serial

Customer

your

with

model infonnation, including

number

and

Identification

Diesel

long

years

take

great

pride

our

selecting the

you

WESTERBEKE.

full

use

operate

to

help observe engine

dealer.

all

require

dealer

manual. A parts

manual

If

your

WESTERBEKE

and

you

PROCEDURES

Warranty

60

days

of submitting

not

received

warranty,

commission

a customer identification

please contact

'~jWESTERBEKE

_ f .

Customer MR. MAIN

HOMETOWN, Model

I •

Exprres

Identification

ENGINE

STREET

____

OWNER

_____

USA

____

_

__

Engine

the

is

a product of

of

experience

in

the

superior

engines

benefit

maintain

do

for

are manual.

date.

and

from

this.

Please

safety

precautions

servicing,

assistance.

catalog

is

available from your

planning

is

included

the

Card

_

Ser.

#.

____

and

advanced

durability

generators.

your

engine,

it

correctly.

read

contact your

is

also

to

install

dealer

for

in a separate

Warranty the

factory

the

engine's

INTRODUCTION

This

this

through-

this

Registry

card

in

_

and

it

is

man-

PRODUCT

Product brochures WESTERBEKE

WESTERBEKE CONTENT OF SUCH

RANTIES

THERETO,

.

COMPLETENESS

BE UABLE FOR ANY

INCURRED OF

THE

WESTERBEKE span and product WESTERBEKE

other sively not

only representatives be

consulted

product

NOTES,

As

this maintenance engine, CAUTIONS,

NOTE:

A

observed,

your

SOFTWARE

software,

FURNISHING

between

the

unavoidable

software.

suppliers,

as

the

makes

software

(technical

and

catalogs),

are

CANNOT BE RESPONSIBLE FOR THE

OR

REPRESENTATIONS WITH RESPECT

INCLUDING

IN CONNECTION WITH

customers

printings of

The

products,

must

definitive

good

of

to

determine

being

CAUTIONS

manual

An operating

takes

schedules,

critical infonnation

and

CAUTION:

can

result

engine.

data,

provided

not

within

WESTERBEKE's control.

SOFTWARE,

ACCURACY,

THEREOF

existence

product

not

sense

WESTERBEKE

AND

you

WARNINGS.

procedure

Procedures

AND

TYPE

OF DAMAGE

OR

USE

should

WESTERBEKE

of earlier WESTERBEKE

software

whether

and

cannot

authority

consulted

but

the

on

is

accuracy

WARNINGS

through

and

troubleshooting of your marine

will

be

An explanation follows:

essential

which,

in

the

damage

parts

lists,

manuals,

from

sources

MAKES

WILL

OR

OF SUCH SOFTWARE.

keep

from WESTERBEKE

be

the

respective product.

imperative

or

the supplier

by

the

operating

highlighted

if

or

other than

NO

WAR-

TIMEUNESS OR

IN

NO EVENT

OR

INJURY

ARISING OUT

in

mind

the

time

product software provided relied

and

customer.

to

not

destruction

with

upon exclu-

that

appropriate

in

question

currentness of

procedures,

by

NOTES,

note.

strictly

of

or

It

the

A

WARNING:

lowed,

can

Engines & Generators

3

Procedures

result

in

which,

personal

injury

if

or

not

properly

loss

of

fol·

life.

INTRODUCTION

SERIAL

The engine's

a The engine's the of enter shown

seeking

UNDERSTANDING

The since are same has rods

Therefore, preventive important nance lubricating

periods (water, Another brand of high detergent specifically

The however, carburetor component function

NUMBER

nameplate

engine

the

number

this

information

below,

techuical

diesel

the

mechanism

arranged

general

the

same

and

lubricating

factors

of the

specified,

sediment,

important

diesel

in its method of handling and

of both.

LOCATION

model

number

mounted

serial

block

number

on

the

one

cylinders

as

this

information

on

will

the

flat

the

THE

engine

closely

is essentially

above a

to

maintenance

fuel,

filter elements

for diesel

engine

and iguition

- the fuel injection pump -

type

as a gasoline

type

of

a great

are

lubricating

and

etc.)

factor

does

closed

valves,

system.

extent,

as

proper

frequent

in

diesel

engines.

differ systems

and serial

side of

can

surface

injection

illustration of

provide

and/or

DIESEL

resembles

crankcase.

camshaft, pistons, connecting

a diesel engine

a gasoline

ventilation

and cooling

must

the

fuel

is

the consistent

from

also

a quick

number

the

be

of

the

pump.

ordering

engine's

found

block

Take

the

reference

are

located

manifold.

stamped

just

the

nameplate

repair

ENGINE

the

gasoline

the

same.

The crankshaft

engine,

be replaced

checking for contaminant's

lubrication oil designed

are replaced

and

engine.

and

system

the

gasoline engine,

frring

which

engine,

The cylinders

the

diesel

requires

The most

proper

systems.

at

the

is

also

essential.

use

of the same

of

fuel.

by

a single

performs

time

into

forward

time

when

parts.

is

engine

the

mainte-

Fuel

The

on

to

the

same

and

the

ORDERING

Whenever engine the silver

must identify description separately packaged

not

made

SPARES

Certain

WESTERBEKE

will

assist

See

the

accessories,

RAW

PARTS

replacement

model

number

and

black

provide

us

your

engine.

and

furnished Parts parts to

the

AND

spares

you

SPARE

see

WATER

parts

and

serial

nameplate

with

this

information

In

addition,

part number

List).

because will

same

fit

specifications

ACCESSORIES

will be

needed

engine.

Your

in

preparing

PARTS

WESTERBEKE'S ACCESSORIES brochure.

COOLING

an

page

SYSTEM

Siphon-Break

For

installations where

close

to

or

will

be below the

must

be

made

to

supply

hose

to

the water injected exhaust

break

provides prevent engine's

A

CAUTION:

the

exhaust

load

waterline

engine

If

you

have injected exhaust elbow relative the

vessels

break.

This

The siphon-break must be

hose

that

the

vessels

above

the waterline during

prevent siphouing.

NOTE:

A siphon-break

cleaning maintain a siphon-break damage.

maintenance.

an air vent

raw

water

cylinders

manifold

and

possible

any

various

precaution

is

looped a

waterline. This

to

ensure proper

Consult

the

water

install a

siphon-break

from

filling

when the

in

Failure·to

injection

will

result

flooding

doubt

about

operating

is

necessary

installed

miuimum

siphon-break

requires

operation.

can

the

siphon-break manufacturer for proper

are

needed,

number

located

for

each Insist

or

to

support local inventory

in

this

vessels

the

engine

always

as

they

on

the

manifold.

so

we

may

include

raw

a complete part

part

needed

upon

WESTERBEKE

generic

injected exhaust

parts

are

as

original

WESTERBEKE dealer

manual.

waterline,

water cooling

exhaust system

is

shutdown.

equipment.

and maintain your

of spare

For

provisions

in

the

raw

elbow.

use a siphon-break

port

is

at

or

in

raw

water

damage

of

the

boat.

the

position of the

to

the vessels

conditions,

to

in

of

20

inches

waterline

install a

protect the highest

your

(51cm)

must

all

angles

of vessel

periodic inspection and

Failure

result

in catastrophic

to

provide the appear

on You

properly (see

the

frequently

parts.

engine

elbow

is

water

The

siphon-

system

and

the

when

below

the

to

the

water-

under

siphon-

engine.

point

of a

above

always

be

operation

properly

engine

to

-.,y

WESTERBEKE

Engines & Generators

4

SIPHON-BREAK LOOPFOR PART

NO.

WITH

1"

HOSE

044010

STAINLESS

DESCRIPTION

TIlls

manually-operated

KEY

switch

and

which

hours.

gauge oil

circuit

voltage.

is

turned

REGIS·

OFTHE CAN

FOR

FROM

THE

PANEL.

measures

The

which

an

OIL

pressure

VOLTAGE

All

The

one

BE THE

meter in

1110

ATIJRE

Fahrenhei~

engine's control

tem's switch is

in.operation.

pushbuttons,

RPM

GAUGE:

TERS

REVOLUTIONS

PER

MINUTE

ENGINE

AND

RECALIBRATED

ACCURACY

REAR

OF

control

RPM

gauge

the

panel

indicates

PRESSURE

in

pounds

gauges

on

and

remain

panel

for

PREHEAT

panel

is

with

an

ELAPSED

engine's

also

running

includes a WA1ER

water

temperature

gauge

per

square

gauge

which

are

illuminated

also

contains

and

one

WATER

TEMPERATURE GRADUATED ILLUMINATED TURNED TEMPERATURE

ON.

IN

WHILE

THE

ADMIRAL

equipped

with

CONTROL

a

TIME

time

in

hours

and

TEMPER-

in

degrees

which

measures

inch,

measures

when

while

two

rubber-booted

for

START.

GAUGE:

DEGREES

FAHRENHEIT

THE

KEY

ENGINE'S

IS

170'-

190' F (77'

and a

the

NORMAL

DC

the sys-

key

the

engine

THIS

GAUGE

SWITCH

OPERATING

-SS'C).

the

AND

IS

PANEL

When

the

engine

the

water

temperature temperature power

was

when

the

key will

once

again

electrical A

Admiral necting electrical the be running. on engine's

separate

Panel.

the

buzzer

audible

The

and

should

oil

power

harness.

is

shut

reading

turned

indicated

off.

switch

register

is

restored

alarm

buzzer

The

installer

buzzer

to

the

The in a location to

the

operator

buzzer

will

silence

pressure

rises

down

with

the

gauge

will

continue

by

the

gauge

The

oil

pressure

is

turned

off.

The

the

engine's true temperature to

the

gauge.

with

harness

is

responsible

four-pin

installer

where

sound

when

OIL

PRESSURE ATED ILLUMINATED ON.

THE PRESSURE (2.1-

it

should

the

above

IN

POUNDS

ENGINE'S

4.2

kg/em').

connection

is

also

responsible

will

be

it

sound

when

the

engine

15

psi

GAUGE:

PER

WHILE

NORMAL

RANGES

BETWEEN

has

(1.1

THE

key

switch turned

to

register

before electrical

gauge

will

temperature

supplied

for

electrically

on

the

with

for

dry

and

where

while

the

ignition

started

key

and

kg/em').

THIS

GAUGE

SQUARE

INCH

KEY

SWITCH

OPERATING

30 -60

the

fall

to

gauge

when

every

engine's

installing

it will

engine

is

turned

the

IS

GRADU·

(PSI)

AND

IS

TURNED

OIL

psi

off,

last

zero

con-

is

IS

HOURMETER: REGISTERS

TIME,

USED

THE

SCHEDULE.

PREHEAT ALTERNATOR'S FUEL ENGINE'S OIL

BUTTON

START

STARTER'S

THIS

UNLESS AT

THE

--;iFD----_

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

EXCITER,

SOLENOID

PRESSURE

BUTTON

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

OPERATE

LIFT

BYPASSES

IN

START

BUTTON.

ENERGIZES

CRANKS

ELECTRICALLY

IS

PRESSED

PUMP,

ADDITION,

ENERGIZES

PUMP,

AND

THE

ENGINE'S

THE

ENGINE.

THE

THIS

THE

AND

HELD

,

~

~ :

...,:

~

'-.-

• ,

AUTOMATIC

.,

COOLANT SUPPLIED REACHES ALARM

OIL

LOCATED THE

FALL ING SIGNAL

ALARM

TEMPERATURE

WITH

THE

210' F (99'C),

WHICH

WILL

PRESSURE

ENGINE'S

THE

OFF

TO

5 -

ALARM.

ALARM:

THE

OIL

10

psi

,

SYSTEM

ALARM:

THIS

SWITCH

AN

OIL

kg/em'),

EVENT,

AN

PANEL.

PRESSURE

GALLERY.

SHOULD

THE

ALARM

INSTRUMENT. EMIT A CONTINUOUS

ENGINE'S PRESSURE.

(0.4 -0.7

IN

THIS

__-1\1"

ALARM

BUZZER

IF

THE

WILL

CLOSE

SIGNAL. ALARM

THIS

THE

ENGINE'S

SWITCH

WILL

SWITCH:

ONLYTO

SHOW

HAS

BEEN

COOLANT

THE

IS

MONITORS

OIL

PRESSURE

CLOSE

SOUND·

PROVIDES

PANEL

POWER INSTRUMENT CLUSTER.

'BATIERYIS

SHOULD

ENGINE'S

SOUNDING

SWITCH

WILL

EMIT A PULSATING

THE

~

WESTERBEKE

Engines. & Generators

5

DESCRIPTION

This

manually-operated

KEY

switch,

an

RPM

tons,

an

INS1RUMENT

lamps,

one

for

AL1BRNATOR

OIL

PRESSURE,

1EMPERATURE.

RPM

GAUGE:

MINUTE

REAR

OFTHE

REGISTERS

OF

PER RECALIBRATED THE

and

THE

ENGINE

FOR

ACCURACY

PANEL.

REVOLUTIONS

control

gauge,

TEST

one

for

AND

CAN

FROM

panel

is

equipped

PREHEAT

button

and

DISCHARGE,

high

ENGINE

BE

CAPTAIN

CONTROL

with a

START

three

indicator

one

for

but-

low

COOLANT

PANEL

The

panel

also PRESSURE RPM and

remains

ALARM: BELOW

PULSATING

TEMPERATURE 210°F

(9goC).

NOTE:

THE SOUNDING PRESSURE

gauge

THE

ALARM

5 -10

psi

SIGNAL.

IN

ALARM

IS

NORMAL.

REACHES

or

is

illuminated

IN

THIS

includes

high

COOLANT

illuminated

WILL

SOUND

(0.4 -0.7

kglcm').IN

THE

ALARM

THE

FRESHWATER

EVENT,

SOUND

ONCE

15

psi

THE

(1.1

WILL

an

alarm

when

while

IF

WILL

ALARM

WHEN

THE

ENGINE

kglcm'),

buzzer

for

1EMPERATURE.

the

KEY

the

engine

THE

ENGINE'S

THIS

ALSO

COOLING

WILL

THE

DIL

EVENT,

THE

SOUND

IF

CIRCUIT

EMIT A CONTINUOUS

KEY

SWITCH

STARTS

AND

ALARM

WILL

low

OIL

switch

is

in

operation.

PRESSURE

ALARM

WILL

THE

COOLANT

RISES

TO

IS

TURNED

THE

ENGINE'S

SILENCE.

The

turned

FALLS

EMIT

SIGNAL.

ON.

THIS

OIL

on

A

START

BUTTON: STARTER'S BUTTON PREHEAT TIME.

SOLENOID

WILL

BUTTON

WATER

TE~IPERATUIRE

ALARM

LIGHT

WHEN

PRESSED,

WHICH

NOT

OPERATE

IS

PRESSED

/

ENERGIZES

CRANKS

THE

ELECTRICALLY

AND

HELD

THE

ENGINE.

UNLESS

AT

THE

THIS THE

SAME

-------

'PO""",,,

o,"m,.·

ALTERNATOR'S

SOLENOID GLOW SURE GIZES

ON

PLUGS,

ALARM

THE

START

EXCITER,

THE

AND

SWITCH.

WHEN

PRESSED,

THE

INJECTION

BYPASSES

IN

ADDITION,

BUTTON.

TURE

CONTROL

CUITS.

WHEN

THE

ALTERNATOR,

OIL

PRESSURE,

THE

WATER TURE LIGHTS ADDITION

ING BUZZER.

""" POWER INSTRUMENT CLUSTER.

FUEL

PUMp,

THE

TEMPERA-

INDICATOR

ILLUMINATE

TO

THE

ALARM

SWITCH:

ONLYTO

ENERGIZES

LIFT

PUMP,

AND

THE

ENGINE'S

THIS

BUTTON

CIR-

PRESSED,

THE

AND

IN

SOUND-

PROVIDES

THE

PANEL

THE

FUEL

ENGINE'S

OIL

PRES-

ENER-

Engines. & Generators

6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a SAE J 3 diesel

Care

Use

in

dirt particles ondmy

important can improper the tank following

Purchase a

to

recommended

Diesel into used.

Install filtedwater separator between The Raycor such

ENGINE

Use a CG-4, initial

filter

SCHEDULE

not synthetic using conventional in

manual

NOTE:

statements

SAE

For

FUEL

diesel

fuel

that

meets

the

requirements of

[3

and

has

a Cetane

fuel

according

Of

The

Fuel

only

clean

diesel

your

engines

filters

be

rendered

combat BACTERIAL

Kleen

the

and

filters. A 10

fuel

which

can

damage

to

buy

clean fuel,

unsatisfactory

storage

facilities.

for

your

engine's

practice

well-known

such

+ Centane Boost

diesel

fuel

regularly

500

MA or 230

micron

injection

might

is

as

when

service a

rating

to

ASTM

Supply

fuel!

The

pump

pass these

and

To

daily

advisable:

brand of

growth

Bio-Bor

an

Ultra

RMAM

filter

of

D975

clearance

is

through

finely

keep

by

careless

ensure

use

is

fuel. in

the

and

an

to

help

Low

good,

visual-type

the

fuel

element

#45

or higher grade of

of

very

the

machined

it

clean.

handling or

that the

clean

The

fuel additive

restore lubricity back

Sulfur

tank

are good

is

recommended.

OIL

heavy

duty

diesel

oil

with

an

API

classification of

CH-4

or

CIA. Change

50

hours

of break-in operation.Then

change

intervals

in

this manual.

approve

the MAINTENANCE SCHEDULE section of

all

or

disapprove

oils

are

used,

oil.

and

not

be

extended if

The

information above supersedes all previous regarding

OIL

VISCOSITY

temperature

synthetic

ranges:

the

as

specified

Westerbeke

the

engine

Oil

change

GRADE

SAB

engine

in

the

use

of synthetic

break-in

intervals

synthetic

oil.

l5W -40 or

oil

MAINTENANCE

must

oils are

No.

2-D

the

components

critical;

primary

use

Corporation does

parts.

The

best fuel

fuel

going into

and

pure,

of additives

tank

is

such

diesel

fuel

and

the

examples

and

filter

follow

oils.

be

performed

must

be

used.

SAB

invisible

and

sec-

It

is

the

as

is

being

engine.

of

CF,

after

the

oil

If

as

listed

this

IOW-40.

and

an

ENGINE

WESTERBEKE and chemicals that

The antifreeze nm the

cooling

quality Additives balanced, crucial

The

being

NDTE:

antifreeze that

PURCHASING

Rather recommends

when

There are

(green) but flush

Premixed antifreeze for DIESEL Engines: Specification #ASTM D53456.

COOLANT

50%

distilled

at

proper

engine

to

circuit

antifreeze

(SCAs)

distilled

poured

Lookfor

than

adding

two

and

do

not

mix

the engine

recommends a mixture

water.

Distilled

can

corrode

performs temperatures the

coolant,

from

that

that keep the

to

water

into

the

is

now

internal

double

by

and

rust

and

corrosion.

contains

long

term

and

antifreeze

cooling

new

environmentally-friendly

available.

ANTIFREEZE

preparing

buying

coolant

Propylene

the

common

the

two

thorougbly.

mixture, WESTERBEKE

premixed

mixture

types

Glycol

and if

of

water

is

free

engine

surfaces.

duty.

It

aHows transferring heat away lubricates

Supplemental

antifreeze

protection.

circuit.

of

(red/purple),

changing

and

Look

should

be

antifreeze

will

always

antifreeze,

from

chemicalJy

MAINTENANCE

Change number of protect

COOLANT

The contraction of

without introducing provided water operating

the

engine

coolant every

operating

and

lubricate

RECOVERY

coolant

recovery

with

coolant conversion kit and

the

engines

fresh

engine.

hours

as

the

engine

TANK

tank

aIJows

coolant

air

into the

water cooled

five

the

chemical

have

system.

models

must

for

years

a limited life.

the

expansion

during

engine operation

This

and

be

50%

antifreeze

from the

the engine

from

protects

premixed before

Ethylene Glycol

either

regardless of

additives that

installed before

for

a good

Cooling

long

so

that

be

correct.

can

one

to

recovery

with

the

lasting

so

that

be

another,

and

tank fresh

to

used

the

is

RECOMMENDED

-

Cruise RPM Models

Model

Maximum RPM (propeller loaded) Models

Model

55BIFour

55DIFour

55BIFour

55DIFour

RPM

RANGES

and

55CIFour

and

55CIFour 2950-3000

2000-2500 2000-2400

2550-2600

rpm rpm

Engines & Generators

7

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before starting prolonged

D

Check at

D

Thrn

examine contaminants.

D

Check

D

Check and

(+)

the

stud

D

Check and

NOTE:

refer

D

Visually parts, the

D

Make

engine.

performance.

D

Make

D

Ensure

transmission.

D

Open to

INSPECTION

your

layoff,

the

engine

the

high

mark

on

the

fuel

the

the transmission the

DC

battery cable

battery

cable is

negative

(this

location

the

coolant

at

the

manifold.

If

the

to

the

COOUNG

examine the

disconnected

threaded

certain

An ample

sure

the

the propeller shaft is securely attached

the

thru-hull

the

raw

water

engine for

check

oil

on

supply,

fuel

filter/water separator

electrical

connections.

connected

(-)

cable

is

level

engine

connections

there

is

supply

mounting installation is

and

strainer.

the

first

the

following

level.

Add

oil

the

dipstick.

then

check the

fluid

level.

system.

Make certain

to

is

connected to

tagged).

in

both

the plastic recovery

luls

not

yet

been filled

SYSTEM

engine.

wires,

proper ventilation

Look for loose

and

unattached

and

engine

is

necessary for proper engine

make

certain

time

or after a

items:

to

maintain

bowl

Inspect the starter solenoid

the

section

attachments.

secure.

raw

fuel

supply for

wire

engine

with

of

this

hoses.

around

water

the

connections

the

positive

ground

coolant, manual.

or

missing

Check

the

to

the

is

primed

level

and

tank

"A<"~P~

":.;:.;j'!j

~1N'"~

19~ti

~

TOP

Oil

Fill

TO

THERMOSTAT

HOUSING

COOLANT

EXPANSION

....v'

WESTERBEKE

Engines'

8

DIPSTICK

& Generators

STARTING·

STOPPING

PROCEDURE

STARTING

1.

Place the control

2.

Thrn

(If

3.

Depress seconds.

4. Continue

the

5. Release

once

6.

With oil temperature thennostat

NOTE:

engine

It Become

PROCEDURE

transmission

to

slightly

the

KEY

the

panel

the

to

START

the

engine

the

engine

pressure

Never

is

running.

is important

aware

immediate

Atmospheric

41'F(5'C)

NOTE:

PREHEAT button PREHEAT

23'F(-5'C)

Limit

of

The

START

button

activates

intermittently

to

conlinuous

in

neutral

open.

SWITCH

is

energized,

PREHEAT

hold

the

BUTTON.

START

starts. running,

and

battery

will

rise slowly

opens.

attempt

to

of

action

to

the

ON

the

gauges

BUTTON,

PREHEAT

BUITON

to

and

check

charging

and

engage

closely monitor the panel

the normal engine readings

if

these

readings

Temperature/Preheat

Temperalure

or

higher

23'F

(-5'C)

or

lower

use

button

is

depressed.

the

glow plugs

will not

to

energize

Depressing

in

avoid

the overheating

and

advance

position

are

and hold

BUITON

PREHEAT

the

instruments

voltage.

then

stabilize

the

starter

start

Preheating Approx. Approx. Approx.

30

seconds

unless

cylinder

the

(2

on.)

for

and

The

while

gauges.

to

vlll)'.

Time

10

seconds

15

seconds

20

seconds

before

the

PREHEAT

head

the

throttle

o'clock).

5 -

10

depress

BUTTON

for

proper

water

when

the

and

take

cranking

the

so

use

glow

plugs.

the

A

CAUTION:

the

engine

starting

system

filling

the

pump

Is

pumping cooling enter manifold from through-hull co"ecting Engine

in

STOPPING

To

place a engine

NOTE:

(12 sound,

FAILURE

In

engine the throttle

system

the

engine's

once

happening

the

damage

warrantable

mind.

PROCEDURE

stop

the

engine,

the transmission

few

moments

down

by

Make

certain

o'clock).

If

warning

TO

the

unusual

off,

shutdown

mechanical

lever

on

shutoff,

issue;

STOP

situation

Prolonged

can

result

with

raw

water.

raw

during

cranking.

cylinders

the

exhaust

by

closing

draining

cause

of

the

resulting

the

owner/operator

bring

the throttle

in

neutral.

to

stahilize

turning off the

this

key

the

key

switch

you

the

key

that the

can

be

stop

lever.

This

the

engine.

cranking

water

in

the

This

may

through

intervals

engine

This

by

way

of

system

the

raw

the

mls.

water

exhaust

excessive

from

raw

water

to

Allow

temperatures,

key

switch.

switch

is

in

is

left

ON,

is

in

the

ON

key

switch

accomplished

stop

lever

exhaust

happen

the

raw

water

the

exhaust

Prevent

supply

muffler,

engine

entry

should

an

idle position

the engine

then

shut the

the

OFF

the

alarm

position.

fails

to

by

pressing

is

located

without

because

water

can

this

and

cranking.

is nota

keep

this

and

to

idle

position

will

tum

the

back

for

the

Starting

Make

prevailing of

NOTE:

CF

Under

certain

temperature.

or

CG-4,

When A voltag,tdrop when

the

preheat

is

depressed.

FAILURE

If

the

5

seconds,

procedure.

neutral prevent

Never fails

engine

position

starting

run

to

start,

TO

wait Make

the

Cold

the

lubricating

SAE

starting:

will.

occur

button

START

fails

to

for

at

certain

as

some

in

gear.

starter

refer

to

Conditions

oil

is

appropriate

Us~oil

with

an

API

15W-40.

12

~6

\

r..a, 0

I.-J

slatt when

least 30

for more

the

start

seconds

the

transmission

engines

then

and

have a neutral

30

seconds.

TROUBLESHOOTING

for

Specification

. -

•..

'\,

"1,;;:,

blltton

is

repe~t

confrQ!

the

.

14

VOI-:TS

pressed

for

the

starting

is

in

the

safety

switch

to

If

the

engine

CHART

in

this

"tOY' WESTERBEKE

Engines & Generators

I

,

IDLE

NOTE:

switch

the

off position.

ENGINE

SPEED

-

-.

-~---

Once failed

STOP

LEVER·---

ADJUSTMENT

-

_.

- .

the

engine

is

shutdown,

to

properly shutdown

investigate

the

engine

why

when

.'

the

key

turned

,

in

9

WARNING

LIGHTS,

ALARMS & CIRCUIT

BREAKER

ALTERNATOR

The

Captain

with a red warning light.

The

Admiral

performance of the

COOLANT

A coolant temperature switch housing. the coolant's operating 21O'F (99'C).

TO

ALARM

BUZi.'E[;>l!l>·

Control

TEMPERATURE

This switch will activate a continuous alarm

WARNINGS

Panel

indicates

Panel

uses a voltmeter

alternator.

SWITCH

is

temperature

alternator

located

reaches

low

to

monitor

on

the

thermostat

approximately

discharge

the

if

LOW

OIL

A

low

oil pressure

block.

This switch's

pressure.

(0.4 -0.7

Should

alarm.

TO

r.nri:rrlnl

ENGINE

The mounted Excessive the breaker because

this

After

.

engine.

CIRCUIT

DC

harness

manual reset circuit breaker

instrument panel

to

the opened

should

repairing the

PRESSURE

kg/cm'), this switch

alarm

sensor

the

ALARM

switch

monitors

engine's

BREAKER

on

the

engine

current

draw

or electrical

wiring

or

trip.

In

this

event most

occur,

breaker

check

fault,

disconnects

and repair the

reset the

SWITCH

is

located

on

the

engine's oil

oil

pressure

will

is

protected

engine

engines

breaker

fall

activate a pulsating

by

(20

amps DC).

overload

wiring

will shut

the fuel

source

and restart

the engine

to 5 -

10

'OIL

PRESSURE

SWITCH

'.~

an engine

anywhere

will cause

down

supply.

of

the

problem.

the

psi

ALARM

in the

If

TWO

WIRES

""""~<u,.

CIRCUIT

BREAKER

Engines' &

10

Gen!1rators

DESCRIPTION

Although hour of test assembly ated your engine and

Breaking-in a ton and scored, break-in period.

Your conditioning operation to Perform lowing:

1.

2.

your

operations

procedures

properly,

serviced

rings

smoky

new

maximize

Start

DURE

that

charging) Allow

fast idle) the

a break-in

is

during

new

to the cylinder

operation

which is caused by

engine

the

this

conditioning

the

engine

section.

all

systems

are

the

engine

until

130

- 140'P

engine

dependent

its initial 50

engine

requires

performance

according

Run

(raw

functioning.

the

(55

ENGINE

has

experienced a minimum

at

the

factory

to

were

followed

time

upon

basically

walls.

indicate that the

overloading

approximately

to

break

carefully,

the

engine

water

to

warm

water

temperature

- 60'C)

and

is

required.

how

the

hours

involves

Excessive

in

each

and

service

keeping

to

the

STARTING

at fast idle

pump,

up

(preferably

range.

cylinder

oil

BREAK-IN

of

one

make

sure

accurate

that

the

engine

oper-

The

service

life of

engine

is

operated

of

use.

seating

the

pis-

oil

consumption

walls

are

the engine during the

50

hours

of initial

moving

life of

in

mind

while

pressure,

by

gauge

part

in order

the

engine.

the

PROCE-

checking

battery

running at

moves

into

fol-

PROCEDURE

3.

While

using

the

vessel,

speeds

for

the

first

25

idling.

4.

Avoid

rapid

acceleration,

5.

Use

caution grey reach

,6.

During varying Avoid

CHECKLIST

o Monitor o .

Check

o

Check vibration

o

Confirm When When When

NOTE:

See

break-in

not

or

black

exhaust

its

full

rated

the

prolonged

the

control

for

leaks

for

abnormal

and

blow-back

exhaust

the

engine

the

engine

the

engine

the

TRANSMISSION

information

to

overload

speed

25

hours,

speeds,

idling

panel

of

fuel

noise

smoke:

is

cold -white

is

warm -almost

is

overloaded -some

on

your

run

the

hours.

Avoid

especially

the

and

the

are

signs

the

with

short

during

gauges.

and

engine

such

sounds.

section

transmission.

engine

prolonged

with

engine.

inability

of

engine

runs

this

break-in

oil.

as

knocking,

smoke.

smokeless.

of

at

various

a cold

The

of the

an

overload.

may

be

at

full

black

this

engine

periods

engine.

presence

engine

to

operated

rated

rpm.

period.

friction,

smoke

and

manualfor

of

of a

at

soot.

Engines. & Generators

11

THE

DAILY

OPERATION

CHECKLIST

Follow

this

check list each day before starting your engine.

, D

Visually

D

Check

D

Check

Periodically check the manifold

D

Check

D

Check

D

Look t\'ansparent bowl.

D

Check

mounting

D

Check

D

Check

D

Visually

STARTING

NOTE:

manual

I,

Put

NOTE:

neutral energizing

transmission

energize.

'2.

Turn

(If

3. Depress the

seconds.

4. Continue to hold the PREHEATBUTTON and

the

5. Release the once the engine statts.

6.

With oil pressure and battery charging voltige. The water

temperature thermostat opens.

NOTE:

engine

inspect the engine for the oil level (dipstick). the coolant level in the

the transmission fluid

your fuel supply.

for

clean fuel

for loose wires at the

is

the starting batteries drive belts for wear and

inspect the raw water

THE

See

STARTING/STOPPING

for

more

the transmission

Hydraulically operated

safety switch

circuit passes.

the KEY SWITCH

the

panel

PREHEAT

START

BUTTON.

START

the engine running, check the instruments for proper

Never

is

running.

in

the fuel

secure.

ENGINE

detailed

is

will

attempt

instructions.

in

neutral, throttle advanced.

through

in

gear so

energized, the gauges are on.)

BuriaN;

BUTTON and PREIIEATBUTTON

rise slowly and then stabilize when

to

engage

fuel,

oil,

or water leaks.

coolant

recovery tank.

coolant

level.

filter/water

alternator

(weekly).

transmissions

which

This

switch

the

staner solenoid will not

to

the

ON

and

proper

tension (weekly).

pump

for leakage.

PROCEDURE

the

starter solenoid

is open when

position (2 o'clock).

and hold for 5 -

t-;

the

starter

separator

while

make sure its

in

this

have a

the

10

depress

the

FAILURE

If

the

5

seconds,

procadure.

neutral

to

prevent

Never

faiIs

this

A

engine tilling pump cooling enter manifold from through-hull

correcting Engine warrantable

in

Stopping

To place

a

few

engine

NOTE:

position(12o'clock}.lfthe

energized

TO

START

engine

fails

to

start when the start wait for at least Make certain the transmission control is

position

run

to

start,

manual.

CAUTION:

the

happening

as

some engines have a

starting the starter for more than 30

refer

in

gear.

to

the

TROUBLESHOOTING

Prolonged

starting

with

is

pumping

system

damage

can

raw

water.

raw

during

engine's

once

the

by

shutoff,

the

cause

resulting

issue;

result

This

water

cranking. cylinders exhaust

closing

draining

of

the

owner/operator

mind.

Procedure

stop

the engine, bring the throttle

the

transmission

moments to stabilize temperatures.

down by turuing off the key switch.

Make

certain

instrument panel

this

in

key

neutral.

button

30

seconds

cranking

in

may

sytem

the

excessive

from

and

seconds.

intervals

the

engine

happen

through

the

This

by

way

of

fills.

raw

water

the

exhaust

raw

water

repeat the starting

neutral

exhaust

because

raw

water

the

exhaust

Prevent

supply

muffler,

engine

entry

should

to

an

idle

Allow the engine to idle for

Then

switch is

key

switch

will

put a

in

the

is

left

drain

OFF

ON,

on

is pressed for

in

the

safety switch

If

the engine

CHART

without

in

the

system

the

water

can

this

and

cranking.

is

not

a

keep

this

position

shut the

the

and

the

battery.

Itisimporttint

Become immedWie

aware

action

to

closely

m'onitor the panel

of

the normal engine readings and

if

these readings start to

gauges.

take

vary.

12

In

order

to

use

this

sary

to

log

your

record

your

engine

NOTE:

Many

of

simple but others

expert

!mowledge

MAINTENANCE

Maintenance

engine

hours.

hours

the

following maintenance procedures

are

more

of

a service

Schedule,

Use

your

by

running

difficult and

mechanic.

engine

time.

may

it will be

require

neces-

hounneter

are

the

or

SCHEDULE

A

WARNING:

while

the equipment correct

terminals

electrical

tools

Never

engine

is

running_

such

as

goggles

for

each

when

servicing

equipment.

attempt

job.

to

perform

Wear

the

and

gloves,

Disconnect

any

of

the

engine's

any

proper

and

use

the

battery

service

safety

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

011

Level

Belts

Inspection

Filter

Batteries

House

Balteries)

Oil

and

Exchanger

Separator

System

Hoses

and

Transmission

Cable

Engine

Water

Pump

Fluid

of

Filter

Zinc

Idle

Level

Engine

Anode

Speed

CHECK

EACH

DAY

0

0 0 0 0

weekly

0

weekly

.

HOURS

OF

OPERATION

100

50

NDTE:

oil

will

inhibit

cool.

Keep

250

engine

the

engine's

500

surface

ability

0 0 0 0

0

0 0

0

0 0 0

0

0 0 0

0

0 0 0

0

0 0 0

750

clean.

0

1000

Dirt

to

remain

0

0 0

1250

and

0

0 0

Diesel

No.2

Check

for

water

if

necessary).

Oil

level

should

dipstick. Check

at

recovery

Add

coolant

Fluid

level

on

dipstick.

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Change

at

Check

electrolyte

and

make

excessive Initial

engine

change

both

Inspect

zinc

exchanger

Change

filter

Initial

check

Inspect

for

tion.

Check corrosion replace

as

tight.

Check

Hose

should

spongy.

Check

for

Lubricate Adjust

to

Remove

the

gasket,

cam

and

seals

Lubricate

MAINTENANCE

rating

and

indicate

if

needed.

should

proper

if

needed.

fuel,

oil

connections.

loose

belt

50

hours

sure

connections

corrOSion.

oil & filter

every

anode,

end

of

every

at

50

leaks.

the

exhaust

buildup

necessary.

casting

be

hard & tight.

and

loose

fittings,

with

WD-40

750

-1000

pump and

(the

shaft

when

reassembling.

DESCRIPTION

of

45

cetane

dirt

in

between

tank;

if

empty,

indicate

between

tension

Check

and

water

tension.

then

every

levels

every

change

250

hours

replace

zinc

anode

200

hours.

hours,

then

Check

anti-Siphon

elbow

on

inside

Check

integrity.

tighten

colter

or

equivalent.

rpm

cover

and

cover

for

can

turn,

fuel

(3/8"

belt

Keep

are

if

all

wear.

or

higher.

(drain/replace

MAX.

and

check

at

MAX

to

1/2"

deflection)

edges

for

leaks.

Inspect

bolts & nuts

250

hours.

50

operating

very

tight.

at

50

hours,

or

once a season.

needed.

Clear

debris.

every

250 valve

for

carbon

passages;

that

Replace

all

connections

hose

clamps.

pins,

etc.

inspect

Check

but

not

clean

if

the

wobble).

filter

LOW

on

manifold.

and

LOW

wear.

wiring

tight.

hours

Clean

off

then

the

heat

hours.

opera-

and/or

and

are

soft

or

impeller,

bearings

(contmued)

Engines & Generators

13

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

by

hounneter

running

time.

gauge

SCHEDULE

to

log your

engine

hours or

record

your

SCHEDULED

MAINTENANCE

Coolant

System

DC

Alternator

Air

Intake

Filter

Transmission

Engine Damper

'Fuel

'Starter

'Preheat

'Engine

Compression

'Adjust

'Heat

Lubricate with

Transmission

Oil

Transmission

Plate

Injectors

Motor

Circuit

Cylinder

the

Valve

Exchanger

Panel

"Lockeze"

Fluid

Cooler

Clearances

Key

Switch

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

0

250

0 0 0

500

0

750

0 0

1000

0

0 0

1250

0 0

0

0 0

0 0 0

0

0 0 0 0 0

0 0 0 0 0 0

Drain,

flush,

appropriate Check

0

DC

bracket; Clean

every

Remove; tested.

Chattering of

damper

Check

spray

condition.

Check and

lubricate.

pinion Check

clean

glow

compound

Check

Adjustments).

Adjust

ADJUSTMENTS).

Remove,

tested.

At

first

Initial 300

hours

MAINTENANCE

and

refill

antifreeze

charge

from

tighten

electrical

100

operating

have

professionally

at

idle

and

plate

wear.

and

adjust

injection

solenoid

compression

Valve

fluid

and

Clean

drive. operation

plugs. on

threads.

Clearances

have

professionally

100

hours,

change

or

at

winterizing.

motor

and

of

preheat

Reinstall

pressure

then

at

DESCRIPTION

cooling

system

mix.

alternator.

connections.

hours.

cleaned

low

rpms

is

l1"emove

opening

for

lubricate

solenoid.

with

and

(see

ENGINE

each

25

hours,

and

corrosion.

anti-seize

timing

cleaned

year

then

with

Check

mounting

and

pressure

an

indication

replace. pressure

Remove

the

starter

Remove

(see

and

at

winterizing.

every

and

motor

and

Engine

pressure

'WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

14

mechanic.

DIESEL

Use ofll45 ASTMD975.

FUEL

A

primary

installed water be

carried

Most installation contaminant's in the

A

typical

is

the separator tank

will

ment. the

fuel impurities. maintaining

FUEL

No:2-D

or

higher.

(SAE

Grade

FILTER/WATER

fuel

filter

between the

and

other contaminant's to

the

fuel

installers include a

package

fuel

filter/water

Rayeor

Model

type

filter

and

engine-mounted

affect

the

fuel

The

owner/operator

reaching

This

process

a proper

the engine's

J313)

diesel

of diesel

SEPARATOR

of

the

water

fuel

tank and

froni

system

on

fuel

filter/water

as

they

are

fuel

can

cause.

separator

500

MA.

Keep

is

not

installed between the

fuel

system,

pump,

engine

is

responsible

injection

is

accomplished

fuel

filter/water

FUEL

fuel

with a Cetane rating

fuel

according

separating

the

engine

the

fuel

the

engine.

separator

aware of the problems that

is

illustrated

in

mind any

filter,

and

for

equipment

by

separator.

to

type must be

to

remove

before

they

with

below.

that

if a water

fuel

supply

water

in

the

injection

making installing and

equip-

certain

is

free of

can

the

This

fuel

SYSTEM

EXTERNAL

PART

FUEL

NO,

2144B

LIGHTLY

WITH

THE

a-RING ONLY REPLACED SIGNS

FILTER

WIPE

CLEAN

NEEDS

OFWEAR

20A

FUEL,~---»-i~~~

GASKET

TO

BE

IF

IT

SHOWS

CIRCUIT

TYPICAL FUEL FILTER

(OWNER

FUEL

The

fuel

the

diesel

fuel

The and

the

it.

If

authorized attempt

FUEL

Periodically

pump

fittings

one

of secured operations.

When

will

flow

A small fuel filter has been added to the incoming fuel

line to ensnre that filtered fuel enters the fuel Iiftpnmp.

INSTALLED)

INJECTION

injection

engine, requiring the utmost care in handling.

injection pump

owner-operator

it

requires

fuel

to

disassemble

LIFT

and

make sure that no leakage

are tight and

the

pumps

'by

the mounting bolt

energized thru

purge

air from the

of fuel

PUMp

pump

is a very has

is

cautioned not servicing, remove it and take it injection

pump

and

important component of

been thoroughly bench-tested

service

facility.

repair

it.

PUMP

check the

as

fuel

secure.

mounting bolts

the

preheat circuit, the fuel

fuel

the engine is

connections

is

The

DC

ground connection

should

to

ensure

system and provide a continuous

running.

to

attempt

to

and out of the

present and that

be clean and

proper

to

an

Do

not

pump

lift

to

service

pump

the

at

well

PRE·FILL

WITH

FRESH

FUEL

FILTERS

The

fuel injection manufactured and from

water

and

must

pass through separator clean, schedule

ENGINE

Periodically check leakage.

.

then

Changing

Refer

1.

2.

3.

4.

5.

6.

7.

S.

and

the engine's

and

change

in

this

FUEL

Replace

follow

the

to

the

illustration

Shut off the fuel Thrn

the fuel Pull the Inspect both Wipe

up Clean off the

pre-filled with

O-ring hand.

The key-on

.fill

Run the engines

filter

the

O-rings

into place

contacts

the

fuel

,ute--

pump

and

the

fuel

they

must

receive

dirt.

To

ensure

this

at

least

two

fuel

spin-on

these

filters

according

manual.

FILTER

the

fuel

connections

the

filter

element after the first

MAINTENANCE

Fuel

Filter

Element

above.

supply.

filter

bowl counterclockwise

element straight down

O-rings

preheat

filter.

over filter

fuel).

the

and

with

the

bowl

Screw

housing.

sequence

and

inspect for

replace

clean

fuel and

small

O-ring.

and

the bowl into

threads. Tighten

injectors are precisely

clean diesel

flow

of clean

filters,

fuel

filter.

to

and

fuel,

a fuel

filter/water

Visually

the maintenance

the

bowl

5Q

SCHEDULE.

to

remove.

and

off.

if

worn.

snap

the

new

(The

bowl

place

the

bowl

firmly

will

allow

the lift

leaks.

free the

inspect,

for

hours

filter

can

when

pump

fuel

be

the

by

to

,.yo

WESTERBEKE

Engines & Generators

15

COOLING

SYSTEM

FRESH

NOTE:

recommended the

Fresh

circulating coolant to engine When

prevented

flow manifold thennostat

, coolant

cooling

fresh

the

Refer

water

heat

the

is

WATER

to

the

antifreeze

water

coolant.

coolant

pump,

then

passes

exchanger

block

via engine by

the

bypassed

from

overheating).

gradually

to

flow

unrestricted

system.

COOLING

ENGINE

absorbing

the

is closed arouud

CoolantRecovery

A

coolant

'"

al\d

significant

the

NOTE:

pressure

are and

recovery tank

contraction

cooling engine

during

loss

of

system.

manifold

COOLANT RECOVERY

TAN,K

Periodically

cap.

Ensure

in

good

condition

closes

tightly.

coolant

'.

'.'w,"'"

CIRCUIT

COOLANT

and

water

is

pumped

through

where

suction

started

opens,

through

heat

the

it

is cooled

side

cold,

thennostat

the

thennostat

As

allowing

to

the external

Tank

allows

engine

operation,

and

without

This

tank

should be

level

and

should be

check

the

condition

that

the

upper and

and

check

Carry a spare

page

for

mixture

from

thennostat

of

external

(although

the engine wanns

for engine

that

cap.

the

engine

the

engine.

into

and

the

circulating

coolant

to

prevent

full

flow

portion

coolant

without

introducing

located

easily

of

the

lower

the

vacuum

to

be

returned

some

of

manifold

the

used

as

by

a

The

the

manifold,

to

the

pump.

flow

is

coolant

the

exhaust

up,

the

the engine's

of the

expansion

any

air

into

at

or

above

accessible.

rubber

seals

valve

opens

CHANGING

The engine's

MAINTENANCE

become

A

COOLANT

coolant

SCHEDULE.

contaminated,

CAUTION:

Proper critical; a substantial traced

back

to

cooling

Drain

the

engine

coolant engine block the system the refill

NOTE:

used

to

A

Wear

Refilling

After exchanger'S

slowly Monitor

the

manifold

pressure Remove

coolant the

cap.

flow After

Coolant engine needed spilled

and

opening

with

fresh

process.

The

help

WARNING:

protective

replacing

poor

the cap.

the

mix

Run

into

checking

should

cools

and

coolant.

Refer

drain

petcock

drain

engine

Beware

gloves.

the

Coolant

the engine block coolant clean,

premixed

coolant

to

the

filler

cap

on

to

halfway between

the

engine

the

recovery

for leaks, stop

draw

down.

check

the

must

be

changed

it

can

lead

cooling

number

system

by

removing'the drain

the

manifold

water,

then

to

the

illustration

on

the

coolant.

of

petcock.

in

the coolant recovery tank

Add coolant

coolant

the

manifold

neck

and

observe

tank.

back

into

coolant in

Then

according

If

the

coolant is

to

overheating

system

of

engine

corrosion.

pressure

reinstall

heat

exchanger

the

hot

engine

drain

plug,

run the

into

and

install the

LOW

the coolant

the

engine and

the

cooling

to

the recovery

the

manifold.

maintenance

failures

the

below.

engille

the

add

and

MAX

system

to

the

allowed

problems.

can

plug

cap.

drain

and

can

coolant.

close

the at

manifold.

as

needed.

manifold

and

fill and

expansion

allow

as

tank

Clean

to

is be

on

the

Flush

start

also

be

heat

idle and

Fill

with

replace

it

to

cool.

the

if

up

any

CHECKING

THE

PRESSURE

CAP

~

WESTERBEKE

Engines & Generators

16-

.

I

COOLANT

DRAIN

COOLING

SYSTEM

THERMOSTAT

A thennostat, engine,

controls continuously the

engine

coolant

from hole

in

the overheating). gradually

.

checked, and

cleaned,

gasket

Replacing

Remove housing gasket, gasket

cap

Run there

AIR

BLEED

FOR

PUSHING

COOLING

the

as

apply

before

screws.

the

engine

are

no

P~https://manualmachine.com/~~~~;;;;~~~

AIR

SYSTEM

located

the

flows

is

first

started,

flowing

thermostat

As

the

opens.

The

·or

the

cap

screws

shown.

a thin

pressing

and

leaks

FROM

THE

near

the

manifold

coolant

through

temperature the

the

(some

coolant

to

prevent

engine

warms

thermostat

replaced

closed

closed thermostat

is

the

exhaust

up,

is

accessible

easily.

Carry

Thermostat

and disassemble the

When

installing the

coat

of sealant

it into

check

for

at

the thermostat housing.

on

place.

Do

normal temperatures

at

the

front

of

the

as

the

coolimt

cooling

circuit.

When

prevents

by-passed

the

new

both

not

through

manifold

thermostat

and

a

spare

therrrio~tat

thermostat

sides

over-tighten

from

can

be

thermostat

of the

and

COOLANT

TEMPERATURE SENDER

a

and

the

that

RAW

WATER

NOTE:

Always install

the

strainer

A clean

engine's strainer

the

glass

in Perform

operation:

1. Close the

2.

Remove

3.

Ciean

4. Replace

5.

Reassemble

6.

Open the seacock.

7.

Run

NOTE:

Also follow

aground.

If

the engine temperature normal may

have

raw

water through the

INTAKE

will

always

raw

water

i,ntake

cooling

when

the following

the

reading,

system.

making

·shoufd

raw

and

clean the

the

glass.

the

sealing

and

engine and

the cause

been

caught

the

STRAINER

the

strainer

be

self-priming.

strainer

Include

your

periodic

be

clear.

maintenance

water

seacock.

strainer

washer

install

the

check

above

gauge

may

up

in

cooling

at or

below

the

waterline

is

a vital component of the

a visual inspection of this

engine

check.

. -

after every

filter.

if

necessary.

strainer.

for

leaks.

procedure

eyer

shows a higher

be

that silt,

the

strainer,

system.

100

after having

leaves

slowing

The

hours

or

the

water

run

than

grass

flow

so

of

hard

.

of

HI-TACK

SEALANT

THERMOSTAT

ASSEMBLY

THERMOSTAT

PART

NO.

47571

BY·PASS

HOLE

WASHER

FILTER

INCOMING

RAW

WATER

SEACOCK

-r'li(l"

~

TYPICAL

RAW

(OWNER

INSPECTAND

CLEAN

EVERY

100

HOURS

WATE:;Riiii~;

INSTALLED)

...v

WESTERBEKE

Engines· & Generators

17

RAW

WATER

The

raw

impeller

lake,

ocean, to the

water through exchanger water

coolant. water-injected exbaust driven

through

HEAT

EXCHANGER

Cool

raw exchanger. the heat of which

is

charged,

through

The

engine

other;

this

harmful

Heat

Exchanger

After

approxiroately

pressure

and automotive radiator

exchanger.)

heat

CODLING

water

flow

pump.

This

or

river

strainer.

the

pump

tubes)

where The exhaust

gasses.

This

'the

water

flows

As

the engine coolant passes

the

internal

then

pumped into the exhaust

The

engine

the

engine

coolant

keeps

the

deposits

test

found

the

CIRCUIT

is

created

by

a positive

pump

draws

from

a thru-hull opening

The

raw

water

to

the

heat exchanger

it

cools

the engine's

raw

water

is

then

elbow,

mixing

mixture of exbaust

stem

tube

and

through the inner

engine

is

conducted

coolant

and

engine's

Service

1000 engine's

shop

(now

the

circuit repeats itself,

raw

water

in

raw

water.

hours

of operation,

heat

should

be able

displacement

water

directly

through

passes

from

(through

circulating

discharged

with,

and

gas

and

overboard.

tubes

of

around

to

the

system

and

cooled)

are independent

exchanger.

flows

passages

to

clean

remove, (A

clean

COOLING

SYSTEM

RAW

The

from

the

strainer

the

heat

into

the

cooling

raw

water

the

heat

these

raw

dis-

back

of from

local and

the

a hose

fresh

the

is

tubes,

water

each

the

clean

test the

non-ferrous

has

within the

On

always (an when operation. are start-up. The periodicallY

MAINTENANCE

NOTE:

(seals purchase a new

a

Close and,

iropeller and

WATER

raw

water

housing

fle«ible

no

iropeller

cautioned

spare.

Changing

carefully pry curved

ing. the

impeller

blades

iropeller

account

be a

spare

kit),

lubricant

Such

raw

for

Should a failure and

bearings),

the

raw

using

an

gasket.

earn

plate

When

assembling,

and

PUMP

pump

is a self-priming,

and a

which

housing,

should

iropeller

Raw

(raw

water)

failures

to

make

water

broken

SCHEDULE,

it

pump

Raw

water

intake

iropeller

the

iropeller

Move

and

gasket.

Neoprene

wipe

producing

this

pump

and

water

is

are

not

sure

raw

pump

or

tom

occur

may

be

and

rebuild

Water

valve.

puller,

out

the

push

the

apply

Qpen

rotary

iropeller.

against

a curved earn

the pumping

be

run

impeller

pump

iropeller

not

present warrantable, water

flow

should

be inspected

iropeller

with

more

Pump

screw

of

blades iropeller

a thin coating

the

pumps

cost

the

Remove

drivers,

the

pump.

to

raw

blades. See

original

Impeller

water intake

pump

The

iropeller

dry.

There

cover gasket

failures

during engine

and

operators

is

present

intern£ll

efficient

to

pump

the

pump

or

pliers,

Install

the

conform

into the

pumps

of

lubricant

to

with

plate

action.

should

aboard

occur

at

parts

as

cover

new

the

hous-

to

valve.

a

TO

TRANSMISSION

COOLER

HEAT

ExC"HANGER

OUT

BOTH

ENDS

A

CAUTION:

impeller,

cooling

they

circuit.

exchanger.

IMPELLER FITS IN

INTO

THE

SCREW

THE

SHAFT

must

SLOT

If

any

be

They

of

the

found

often

vanes

to

can

have

prevent

be

found

broken

off

blockage

in

the

heat

in

the

COOLANT

DRAIN

TO

IVlMI'VlrVlev

TO

THERMOSTAT

HOUSING

EngInes' & Generators

18

RAW PART

WATER

NO,

11361

PUMP

ZINC

ANODE

A zinc

anode,

or pencil,

circuit within the heat

anode

is

to

sacrifice itself

in the

raw

water cooling circuit, thereby reducing the effects

of

electrolysis on other components

condition of the zinc

the anode cleaned or replaced should be carried on

NOTE:

Electrolysis

and

vessel

location;

is

exchanger.

anode

board.

is

the

not

that

'located in

to

should be checked monthly

result

COOLING

the

raw

water cooling

The purpose of the zinc

electrolysis action taking place

of

the

system.

The

and

as

of

the

required.

each

Spare

anodes

particular installation

engine.

SYSTEM

If

the zinc pencil needs replacement, hold the which the loosening the hex removing the zinc, note the condition poor.·condition, exchanger. Remove the inside exchanger end gasket damaged

(refer

number),

NOTE:

not

insulate housing

NOTE:

thot a heat every

zinc

pencil

is

threaded with a wrench while

anode

with another wrench. This prevents the

boss from possibly tearing off the exchanger shell. After

there

are

probably zinc flakes within the

the

end

of

the heat exchanger and clean

of

all

zinc debris. Always have a spare heat

in

case the present one becomes

when

removing the end

to

yoor engine model's heat exchanger end gasket part

a-ring,

cover,

and

The

threads

require

the preventing

Operating

1000

of

sealant.

zinc

Sealant

from

electrolysis

in

silty

exchanger

hours.

the

zinc

the

metal

and/or

cleaning

cover.

install a new

anodes

are

should

not

of

the

action

tropical

be

peiformed more

hex

of

it.

If

the zinc is in

Replace the gasket

zinc

pipe threads and

be

used as it may

heat

exchanger

on

the

zinc.

waters

boss into

anode.

may

-

require

often

do

than

NEW

ZINC

REPLACE

ANODES

I

AIR

INTAKE I SILENCER

Description

A marine diesel engine running at high speed will typically consume more than 6,000 cubic feet must the engine room be well ventilated, the air engine must be unrestricted.

Air

Filter

The

air

filter cartridge prevents engine room dust and dirt

from entering the engine, it also improves oil consumption, extends engine life, and quiets the engine.

of

air per

hoor.

flow

Maintenance

The

filter

should be cleaned every 100 operating hoors. the cartridge on a with compressed air.

. ,

oily,

replace

it.

flat

surface to dislodge dirt or clean off

If

the cartridge

is

badly contaminated

Not only

into the

Tap

or

INSTALL THE

HOUSING

OF

THE

FILTER

HOUSING.

THE

HOUSING

.

OF

THE

FILTER

THE

HOUSING.

AND

..,......,

THE

FILTER

WITH

FACING

PRESS

THE

LEAVING

PROTRUDING

THEN

HOUSING·

AIR

FILTER

CARTRIDGE THE

OUT

CARTRIDGE

APPROX

INSTALL

ONTO

INTO

SCREEN

OF

THE

1/8"

FROM

THE

BASE.

SIDE

INTO

CARTRIDGE

IF

THE WITH WITH

IF

THE CARBON

FILTER

ELEMENT

DRY

DUST

OR

COMPRESSED

ELEMNET

OR

DIRT, AIR

HAS

ACCUMULATED

GREASE,

IT

~

.

IS

CONTAMINATED

IT

CAN

BE

FROM

MUST

CLEANED

INSIDE

OUT

BE

REPLACED.

WESTERBEKE

Engines

& Generators

19

.

ENGINE

LUBRICATING

OIL

ENGINE

Use a heavy pr hours thereafter. (oil the

CHANGING

The

from allow hose is

properly

beep

CG-4

or

of

break-in

viscosity)

life

of

engine

its

attacbment

the

and

pump

drained.

OIL

duty

better.

For

recommended and

the

engine.

THE

oil

should

oil

to

drain,

the

secured

engine

oil

with

Change

operation,

stay

ENGINE

with

be

warm.

bracket

or

attach a pump

old

oil

out.

in

its

holder

the

and the

OIL

and

an

engine

every

oil

use

same

Remove lower

Make

after

API

classification

oil

after

an

250

hours

SAE

I;iW-40

brand

of

the

oil

it

into a container

to

the

end

sure

the

oil

all

of the

8mm-11/16"

SDCKET

initial

of

oil

drain

old

of

50

operation

thru-out

hose

of

the

hose

oil

has

CF

.

and drain

OIL

SEALING

APPLI'CLEAN

GASKET''---

ENGINE

CHANGING

When

punch a hole t?.Qrain to

lessen

helpful in

and

a plastic

any

oil that's in

removed

off

with sealed installing

sealing

t1tin

coat

the

oil

and

tighten

THE

removing·the

in

the

oil

spillage.

removing

bag

to

make

the

old

against

the

surface

of

clean

filter.

Screw

the

OIL

FilTER

used

oil

filter,

the

upper

and

into

a container

An

automotive.'filterwrench

the

old oil

around

the

filter

the

filter.

Inspect

sure.that

oil

the

oil

new

oil

on

the

engine

filter'finn!y

filte,.

filter

oil

the

If

adapter,

filter

oil

filter

this

clement;

to

onto

by

you

lower

before

filter.

when the

rubber

adapter

the

rubber

the

hand.

may

portion

removing

Place

unscrewing

old

oil

sealing

gently

wipe

the

free

sealing gasket

threaded

SPIN-ON

TURN

find

it

helpful

of

the

old

it.

This

should

some paper

it

filter

as

gasket

rerriove

of

filter

oil

it

gasket's

a'1.d

filter

OIL

ON

HANO

filter

helps

be

towels

to

catch

it

is

comes

remaiqs

When

apply

on

stub,

FILTER'

TIGHT

tu

a

A

WARNING:

contaminants. and

nails discard used

Always emulsion this prevent

is of a a

siphoning

.

exhaust,

oil

observe

condition

serious

present

fault

clothing

properly.

indicates

in

in the exhaust

filling

Used

Avoid

thoroughly

or

rags

the

old

the

is

rare,

it

damage.

the

oil.

Water

through

the

it

up

into

engine

oil

contains prolonged using

oil

presence of'water in

does

Call a

systep:!

water cooling circuit into

theengine.

skin

contact.

soap

and

water.

containing

as

it

require

present in

used

is

removed. A yellow/gray

prompt attention

competent

the

oil

attacbed

to

oil.

the

mechanic

can

the

harmful

Clean

Launder

Discard

oil.

Although

if

be

the

engine

the

skin

or

to

water

result

and/or

NOTE:

Use

genuine

are

not

recommended.

REFilLING

Add

fresh

run

the

oil

pressure.

oil

filter

en~e:

dipstick Fill

oil

engine

or

from

Then

THE

through

for a few

Make

check

to

WEiJTERBEKE

Oil

SUMP

the

valve

moments

sure

there

the

oil

drain

the

quantity

the

FULL

mark

oi/filters. Genericfilters

cover.

After

refilling

while

checking

is

no

leakage

system,

of

on

TDP

OIL

and

oil

with

the

dipstick ,

around

then

the

engine's

the

stop

the

lube oil'

oil,

new

-..y'

WE$TERBEKE

Engines & Generators

20

INSTALLATION

This

popular

ter

from

engine

NOTE:

instructions

To

install,

WESTERBEKE's

install

Contact

accessory

the

engine

room

bulkhead.

Refer

to

ENGINE

on

simply

this

kit

with

your

WESTERBEKE

is

to a more

removing

remove

remote

the

oil

used

OIL

CHANGE

the

oil

the

oil

filter

REMOTE

to

relocate

convenient

filter.

engine filter

facing

dealer

oil filter

kit

as

down

for

the

location

in

this

shown.

as

more

OIL

engine's oil

such

as

rtUInualfor

and

thread

Always

illustrated.

information.

FILTER

NOTE:

filan

on

incorrect

A

rectly. pass from failure. Immediately

(OPTIONAL)

Westerbeke

installation

CAUTION:

If

valve

reaching

If

the

in

there

is

oil

the

and

not

of

it

is

flows

filter

engine

Is

no

check

responsible

the

Remote

vital

to

instal/the

In

the

reverse

assembly

causing

oil

pressure

the

~~~,ctij~ns.

for

engine

Oil

Filter.

direction,

will

prevent

an

internal

reading,

failure

011

lines

the

engine

shutdown.

cor·

the

oil

due

by·

to

THE

OUT

CONNECTION

MUST

ATTACH

OIL

TO

ATTHE

FILTER.

CONNECTION

REMOTE

THE

IN

APPLY A THIN

INSTALLING

TIGHTEN

CONTACTS

COAT

THIS

AN

ADDITIONAL

THE

OF

KIT.

BASE.

CLEAN

OIL

THREAD

THE

3/4

TURN

~~

__

,-

TO

THE

O-RING

KIT

ON,

AFTER

THE MUST

WHEN

THEN

HAND

THE

O-RING

IN

CONNECTION

ATTACH

TO

iC;.O,NMN'iETC,TION

OIL

FILTER.

AT

THE

HOSE

OUT

APPLY A THIN GASKET

WHEN

CONTACTS

THE

COAT

OF

CLEAN

INSTALLING.

BASE,

AfTER

TIGHTEN

OIL

TO

THE

IT

AN

ADDITIONAL

FILTER

~

WESTERBEKE

Engines & Generators

21

WATER

These

of

The

either that

run in a

trap Hoses

heater heater then

on the heater for

NOTE:

engines

remote

circuit

tank

connections for

single

engine s return.

convenient location

The

system fill

when the remote expansion tank

tank

recovery

HEATER

engines

engine

coolant to

water

heater

in

a high or

the

connecting

reasonably

air.

should to

the engine

to

the

an

air bleed

Ifany portion

own

expansion

to

become

into

the

line

up

remote

point.

serves

tank

INSTALLATIONS

are

equipped

should

low

hoses

direct

rise

continuously

engine.

petcock

bleeding

pressure

tank

the

heater

the

return.

to

the

Install

expansion

The plastic cooklnt recovery tank

the same function.

if

it

has

with

transfer

so

If

circuit,

tanks

so

heat

be

mounted

position

that trapped

of

cap,

(Kit

highest

the

tank

been

in

from

the

line

without

from

air will

air

must

be installed

air

while

the

heating circuit

then

#024177)

point.

choosing

Tee

at

location and the other back

remote

coolant level

will

already

connections to

an

on-board

in

a convenient

relation

a pressurized

the

now

kit

Rel1W1!e

to

heater

to

any

loops

their

low

rise

naturally

is

able

to

filling

the

rises

must

Tee

the

higher

heater,

expansion

can

serve

as a check

is

installed, since

and

installed.

at

be

WATER

for

the

plumbing

water

heater.

location

the

engine,

the

engine

can

which

point

at

the

from

the

rise

to

the

heater,

the

higher

system.

above

the

(aluminum)

installed

remote

expansion

of

the

two

and

plumb

to

tank

in

a

easily

be

checked. and

is

not used

store

the

plastic.

so

might

fitting

in

the

a

the

this

HEATER

The

pressure installed coolant.

tank

after good the

engine's coolant

not

at heater supported enabling of

the

NOTE:

heat

exchanger.

coolant

Close

cap

after the engine's

Finish

filling

the system

coolant circulation.

the engine

to

the any

system.

An air bleed petcock is located

system

tightly after all

remote

so

it

manifold

rises

air in

Open

to

on

the

engine's manifold should be

cooling

the

cooling

is

filled

During

should

cap.

expansion

cOl)tinuously

the

system

this

petcock

allow

air

the

air

system

and

is

free

engine operation, checking

be

done

at

The hose connection

tank should

from

to

rise

up

when

in

the

exchanger

is

removed.

is

filled with

from

the remote

of

air

and exhibits

the remote tank

be

routed and

the heater to the tank,

to

the

tank and out

on

the

engine

filling

the

to

and

from

~

engine's

escape.

the

'~""'ml"

1WO

mT/Ntis

HOT

WATER

CONNECTIONS

.

THIS

WATER

HOSE

AND

HEATER

CONNECT

HOSES

TO

THE

THESE

~

WESTERBEKE

engines & Generators

22

TACHOMETER

TACHOMETER/HOUR

The tachometer/hour meter used

instrument

with

and the other the tachometer. The hour meter circuit operates

12

on tenninal on the back of the instrument.

The tachometer circuit operates from one

tachometer

the alternator producing battery charging voltage 13.0-14.8 volts

The following me procedures

ing a fault

meter.

Hour

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

terminals.

1.

2. Voltage not present - ttace

Tachometer

Check for the proper AC voltage between tachometer input

tenninal

1.

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

3. Check for AC voltage at tach terminal on alternator

4.

Tachometer

1.

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

. tenninal

3. Check that alternator is well grounded

Tachometer

a. Using a hand held strobe tachometer reading front crank

b. Using the

c.

panels

a common

volts alternator charging voltage supplied

ground.

of

the diodes in tl,e alternator and supplied

input

DC.

in

either

Meter

Voltage present - meter

connections for fault. (Jump

terminal to verify the operation.)

Inoperative

and

(-)

temlinal

Voltage present - attempt adjusting meter through

calibration access hole. No results, repair

meter.

output voltage.

ground.

Check

electrical connections

tenninal

to

alternator

Sticking

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

and

alternator pivot bolt.

Inaccurate

shaft pulley speed. Adjust the engine speed

engine

rpm

..

coal'S

puts tile panel tachometer rpm reading the closest to the

strobes

Using a 5/64 (2mm) allen wrench, adjust the calibration

strobe

pod

tachometers

on

the

panel

tachometers

METER

contains

terminal

alternator.

two

One

circuit

while

of

the

two

is

defective - repair or replace.

with

connection.

adjustment, select

rpm

reading.

tachometer

rpm.

in

propulsion engine

separate

to

circuits

(+)

the

electrical

operates

on

AC

voltage 6-8 volts, fed

the

engine

follow when troubleshoot-

the

is

mnning,

circuits

hour

to

the (+)

in a tachometer/hour

and

(-)

electrical

12

valls

DC

to meter (+)

engine

running.

or

replace

from

tachometer

to

read

A,

B, 4, 6, or 8 that

the

input

to

engine block at

to

112

same

as

meter

to

the

and

to

rated

the

COARSE ADJUSTMENT

TACHOMETER

NOTE:

In a new

the

tachometer

engine s rpm.

CHECK

installation

may

n.ot

This

calibration

(New

having

always

Installation)

new

instrumellt

be

correctly calibrated

should

be

checked

installations.

1.

Warm

up

the

engine

to

nonnal

operating

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.

3. Aim the light of the tachometer onto the reHecting tape to

confirm the engine speed. Check the instrument panel

tachometer reading. Adjust the tachometer in the panel

by

using

the

instrument

instrument reading

is

showing. Then use the fine calibration adjustment bring the instrument to the exact reading tach.

4.

Set the tachometer

has been factory adjusted and the idle screws and high speed screws have been locked

•

.

~

.~

~

I

-

r

-

~

1--

----~

Oil

p~[Ss.

~

~3'\""

~

L~@

~

":'J,,

mSNlTtll

of

suitable reflecting tape on the

of

a photoelectlic type tachometer.

coarse

adjustment

to

the closest rpm that the photo tach

to

the idle speed (the engine idle speed

in

I~

m

"jIl'(~

III

YOLT~(lU

110

~co

;}.

•

i

,

------

-

eu@

~

'I~

i

II~

l~

rro

~G~UG(

~~,)

III

BL~~~

J<..o-

(0:

I

temperature.

as

place).

-

0~

'",

~o,

'0)

A(O

Iliij[C

to

TERMINAL

panels,

to

in

all

n.ew

calibrate

the photo

I

-

:J®

the

to

i

I-

"""

WESTERBEKE

EngInes & Generators

23

ALTERNATOR

The

charging with a voltage regulator, mounted cables. electronic voltage regulator internally

#14

GRA'r==::!¥==;:I.---~,-....L'"

#14

PPlll~NK~~~~~

#1481

ALTERNATOR

. A

WARNING:

hot.

Do

Use

this exists determined that the alternator

have a qualified technician check

The alternator charging circuit

and the or a battery to

isolate the batteries along starting the

service

tor.

Testing

system

DC

circuit

Because of

or

on

the

ENGINE

GROUND

TROUBLESHOOTING

not

touch

troubleshooting

with

the

charging circuit

service

battery.

selector switch

with

the service

battery

but

battery's

the

Alternator

consists

breaker

the

use

back

A

failed

until

An isolator

so

battery.

not

the

charging

of a

an

engine

and a battery

of

integrated

is

very

of the

alternator.

alternator

the

alternator

section

to

or

voltage

it.

charges

is

usually

the starting

If

the

service

circuit

DC

ELECTRICAL

DC

belt driven alternator

DC

wiring

harness, a

with

connecting

circuits (IC's), the

compact

determine

with

with a diode,

battery,

and

is

AMP

1Ilm==1110RED

SEE

WIRING

FOR

WIRE

TO

OPTIONAL

can

become

has

cooled

if

a problem

the

alternator.

regulator

the

starting battery

a solenoid

mounted

battery

alternator

and

in

is

not

is

charging

the problem

not

with the

mounted

ALTERNATOR

DIAGRAM

CONNECTIONS

ALTERNATORS.

very

down.

If

it

is

faulty,

the circuit

discharged

the

is

in

alterna-

SYSTEM

1.

Start

the

engine.

2.

After

the

engine

has

battery

starting

multimeter a.

If

the

tor

is

to

"Checking

b.

If

the exists continue

TESTING BATTERY/ALTERNAT {ENGINE

3.

Turn

off

Ensure

that the

connections

A

CAUTION:

charging switch

4.

If a

battery

ensure

that

5.

Tum

on

6.

Check

the

tion,

the

voltage

set

on

voltage

working;

voltage

is the

remains

with

either

with

Steps 3 through

MUlTIMETER

THE

START

RUNNING}

the

engine.

battery

are

tight

circuit,

when

the

selector

it

is

on

the

ignition

battelY

reading

run

at

DC

volts.

increasing

omit

Steps

Service

the

alternator

ING OR

-

Inspect

terminals

and

To

avoid

never

engine

switch

the

correct

switch,

voltage.

should

for a few

the'

around

minutes,

battery

toward

3 through 8 and

Battery"

12

or

8.

OOD

0

COM

e

eeee

"r:

......

-=

GROUND

all

wiring

and

clean

..

damage

shut

off

the

Is

running!

is

in

the

setting.

but

do

If

the

battery

be

12

to

13

measure the

terminals using a

14

volts, the alterna-

go

directly

on

the.next

volts,

the charging

e

STARTING

and

the engine

to

the

engine

charging

not start the

is

volts.

page.

a problem

circuit;

G:>

S

.J

BATTERY

connections.

ground

battery

circuit,

engine.

in

good

condi-

A

CAUTION:

that

everyone

sheaves

A

DC applications.

isolate

before

made

and

WARNING:

and

AC

DC

performing

without a proper

Before

is

clear

belts

circuits

Always

and

AC

starting

of

moving

during

test

procedures.

When

testing

are

often

disconnect a shore

converters,

DC

testing.

know/edge

with a multimeter:

mixed

and No

the

engine

parts!

together

shut

AC

of

tests AC

make

Keep

in

power

down

should

circuits.

certain

away

marine

cord,

the

engine

from

be

Engines ·&·Generators

TESTING

ALTERNATOR (IGNITION

24

THE

VOLTAGE·

ON • ENGINE

OFF)

':;'

@ID

G

COM

-I- .w..--MUlTIMETER

GROUND

7.

Now

minal

the

tor

is

neither between connections

check

(B+)

alternator

in the

of

the

voltage

and

ground.

will

be

circuit

the

above

alternator

-look

between

If

the

circuit

the

sarne

as

alternator

is

true, a problem and

the

battery.

for

an

opening

DC

the

alternator

is

good,the

the

battery,

voltage

will exists Check

in

the

MULTIMETER

ELECTRICAL

output

or if be

zero.

in

the

all

the

charging

,I

CI2ID

ter-

voltage

an

isola-

If

circuit

circuit.

at

Checking

Check have a voltage running. charging circuit isolator,

SYSTEM

the

Service

the

voltage

If

circuit.

by

checking

battery

between

not,

there

Troubleshoot

switch,

of

the

is a problem

the

Battery

service

13

and

wiring

and

the

battery.

14

volts

in

the

service

and

connections,

battery

This

battery should

when

the engine

service

battery

itself.

battery

charging

the

solenoid,

is

STARTING

TESTING

eeee

BATTERY

e9

EB

.-

ALTERNATOR.

THE

STARTING

BATTERY/ALTERNATOR

8.

Start alternator

The should is service

NOTE:

voltmeter at tery

If

wiring

(ENGINE

voltage

over-

the

voltage

12

RUNNING)

the engine

output

reading

be

between

or

under-charging,

facility.

Before

removing

to

ensure

EXC

terminal

at

volts

is

not

and wok for

again.

and

13.5

the

B output

present at

Check the

ground.

for

a properly and

the

that

12

if

the

breaks

•

voltage

operating

14.5

volts.

have it

repaired

alternator for volts

DC

and poor

terminaL

EKC

test

terminal,

'~

COM

I

~=--'

""

between

alternator

If

your

alternator

at

a reliable

repair,

excitation

showed

connections.

is

only

trace

~

ENGINE

GROUND

the

use

a

present

bat-

the

MULTIMETER.

GROUND

A

CAUTION:

do

not

use a high

pedorming

i

COM

e

tests

Til

avoid

voltage

on

the

TESTING BATTERY

damaging

tester

(i.e. a megger}

alternator

•

ALTERNATOR

•

SERVICE

THE

(ENGINE

the

alternator

charging

BATTERY

SERVICE

RUNNING)

diodes,

when

circuit.

12

VOLT

DC

The

engine

has a

shown

on

the·

diagrams

electrical

A

circuit, the however, engine's

when system.

CAUTION:

never

engine

is

to

electrical

BATTERY

The

minimum

the

engine's

Cranking

12

Amps

CONTROL

12

wiring

troubleshooting

To

shut

running.

avoId

recommended

volt

(CCA).

CIRCUIT

volt

DC

diagrams

avoid

damage

off

the Shut

electrical

circuit.

DC

control circuit

electrical

that

follow.

or

when

engine

off

the

sholfs

capacity

control

servicing

to

the

battery

engine

when

of

the

is

600

.

circuit that

Refer

to

switch

battery

working

battery

- 900

~

Battery

these

the

is

DC

Review establish a systematic engine's

o

charging

while

switch, on

the

o

o o

o

used

in

Cold.

WESTERBEKE

Engines.& Generators

25

Care

the

manufacturer's

starting

Monitor engine

Check hydrometer.

Use

level.

Make tight

Keep

A

cause protective

your voltmeter

operation.

the

only

distilled

certain

to

the

your

WARNING:

severe

gear.

maintenance

batteries

electrolyte

water

that

battery

posts

batteries

Sulfuric

burns

on

recommendations

schedule

and

house

batteries.

for

proper

level

and

specific

to

bling

electrolytes

cable

connections

(and

to

your

clean

and

free

acid

in

lead

skin

and

damage

and

for

charging

gravity

engine).

of

corrosion.

batteries

clothing.

then

your

duling

with a

to

a proper

are

clean

can

and

Wear

GLOW

PLUGS

DESCRIPTION

The

glow

plugs

are

wired When should

PREHEAT

"click"

on

is

pressed

and

INSPECTION

To

inspect

the

plug,

remove tions,

then head. soft oil

deposits.

bum

brush

unscrew

Thoroughly

and

erosion;

cleaning

While

if

it

or

clean

cleaning,

has

eroded

TESTING

An

accurate Touch other plug used an

multimeter

A

to

the

testing

way

to

test

one

prod

to

the

to

the body of

will

have a

with

the plug

WARNING:

touch.

the

1.0 -1.5 in

to

test

These

Be

careful

plugs.

the

or

the

through

the

glow

unclamp

each

solution

glow

ohm

out

power

glow

not

the

preheat

at the control panel

plug should

the

electrical terminal

each plug

plug's

tip

to

remove

examine the

too

much, replace the

plugs

is

with

plug's wire connection,

plug,

as

shown. A good

resistance.

of the engine.

drain

(8

plugs

will

to

burn

your

begin

from

and

threads

all

tip

for

an

This

You

- 9

amps

become

fingers

solenoid.

this

solenoid

to

get

connec-

the

cylinder with

the

carbon

wear

and

plug.

ohmmeter.

and

glow

method

can

per

very

can

also

plug).

hot

when

hot.

a

and

the

use

be

Re-install plugs seconds. circuit. compound

A

than

GLOW

the

should

If

When

on

WARNING:

30

seconds.'

PLUG

TIGHTENING

1.0·1.5

plugs in

get

the plugs don't heat

reinstalling the

the

very

threads.

Do

M-KG

the

engine

hot

(at

the terminal

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28

DESCRIPTION

111e

starting

system

and

starter

button.

When

the

starter

button

current

flows

and

energizes energized into

to

serves

flywheel. 10

pinion is engine motor

Once pUlg contact flow

..

magnetic plunger from

TERMINALS

file

reach

to

prevent

gear

splined

may

itself.

tlle

the

with

of

electricity

is

its

coil

becomes

coil,

and

closes a set

tlle

starter

motor.

push

lImt

starter

danmge

incorporates

to

the

starter

speed

tlle

started

button

activation

oftlle

1I1e

battery-to-start

is

fielda

and

released,

engagenlent

___

includes

on

the

tlle

an

electroillllgnet,

At pinion

to

tlle

starter

an

over-running

annature

rotation

is

released,

solenoid.

intenupted

the

starter

its

movement

with

the

.,"

tlle

battery,

instrument

starter's

of

contacts

tlle

same to

mesh

motor

shaft.

of

1I1e

pulion

the

The

cables

to

1I1e

ceases

also

engine

......

~_

starter

panel

solenoid

which

time,

the

witll

when1l1e

(one-way)

111e

rotation

but

current

plunger

by a coil

starter.

This

its

rotatiOlL

pulls

the

flywheel.

SOLENOIO

STARTER

motor,

solenoid,

is

depressed,

coil.

111e

pulls

tlle

plunger

allow

high

cun-ent

plunger

also

the

teetll

on

1I1e

engine

starts,

1I1e

clutch

which

of

1I1e

nnming

not

tlle

starter

flow

ceases,

stop-

is

pulled

out

of

spring,

and

the

weakeus

As

starter

the

solenoid

drive

the

gear

MOTOR

IGNITION TERMINAL

TO

CONTROL

PANEL

To

test

tlle

ignition

oftlle

small

tenniIJal Use a screwdriver, ignition

111e

solenoid.

If

the starter

If

the

solenoid

motor

tenniIJal

is

to

cranks,

c1lcks

probably

circuit,

studs

don't

touch

the

positive

the fault

but

faulty.

ioc,lIe

Ihe

and

is

the

battery

lies

nothing

~

___

--~IIMI

n

:igJlitioni(s)

wu'ecll:0

ttle

Illllltloncrn'Ult).

blade,

to

junlP

comlection

with

the

ignition circuit

else

happens, the starter

(+)

POSITIVE TERMINAL

tenniIJal

from

tenniIJal

TERMINAL

(it

is

one

that

on

MOTOR--fiVdlic+

TYPICAL STARTER

MOTOR

TROUBLESHOOTING

Prior

to

testing,

roake

certain

the

ships

and

11mt

tlle

startiIlg

system

wiring

clean

and

tight.

Pay

.

connectious To

check

never

111e

wires

resistance. Using a multimeter,

stnd

If

you

more

on

read

111e

and

Repair

111e

on

the

wiring,

11la1l

temrinals

staJt

12

volts,

particular

engine

try

10

seconda

or

replace

test

solenoid

ale starter

attention

block

cranking

at a time,

looking

any

the

voltage

and

1I1e

for

trouble

batteries

COlmections

to

the

111e

starter

then

run

warm

spots

spots.

between

engine

block

is

faulty.

are

at

(terminals)

ground

for a few

your

tlJa!

iIldicate

the

positive

(ground).

full

charge

wire

seconds,

hand

along

tenninal

are

~:Jl.6

IGNITION TERMINAL

TO

CONTROL

PANEL

If

noaJing Check CODIJectiOllS.

A

fly space

at

all

the

battery

It

WARNING:

when

jumping

is

free

gasoline.

;:!~~~iQ-----(+)

.

~...--

happens

is

also

of

the

isolation

switch

possible

There

terminals.

potl!ntially

solenoid

that

will

be

Be

explosive

iSD't

and

iIlspect

111e

solenoid

arching

ceriain

getting

the

and

the

fumes,

(M)

TERMINAL

~

current.

wiring

is

defective.

sparks engine

especially

POSITIVE

TERMINAL

will

Engines & Generators

29

.

IGNITION TERMINAL

TO

CONTROL

PANEL

Test

again

by screwdriver screwdriver would

cause a short

A

WARNING:

starting

current

screwdriver.

jumping blade blade

the fumly to

touch

There

shOUld

R....---(M)

two

large

between

the

solenoid

will

be

flowing

~/'

tenninal

tile

studs.

be

arching

or

starter

thru

(f)

POSITIVE

TERMINAL

studs.

Do

not

casing,

as

the

blade

STARTER

Hold

tile

allow

tile

MOTOR

)

this

full

of

the

SERVICE

Westerbeke serviced

If

replacing cerlified standards.

TO

1.·

Discol1lJect

2.

If

starter

3.

Label wires

4.

Remove

5.

Remove

will

uses a S1>mdard

or

rebuilt

the

ror

marine

If

in

REMOVE

necessary,

motor.

and

disconnect

to

touch,

tlre the

have

to

at

starter

use.

dO)lb!;

FOR

the

negative

remove

tape starter starter

be

1llmed

marine

any

starter

motor

motor,

meke

Automotive

contact

your

SERVICE

battery

any

components

the

wiring

over

tile

tenninaIs). mounting from

bolts.

the

engine.

to a different

starter

motor

which

automotive

certain.

starters

tile

do

new

not

service

motor meet

WESTERBEKE

cable.

to

gain

full

from

tile

starter.

(Do

In

some

cases

angle

to

clear

can

be

center.

is

USCG

dealer.

access

to

the

not

allow

the

starter

obstructions.

If

the starter

If

the starter falls to

If

no

NOTE:

the

pre-engaged

engages

screwdriver

motor

provide

magneticfieldfor the

solenoid

arcbing

Starter

the

without

the

power

spins,

occurred. There

nwtOl"

sta/wr to

bypass

engaging

are

the

spin,

model,

motor

the

to

the

ann

bad.

solenoid

the motor

are

either

the

solenoid

to

the

solenoid

the

flywheel

solenoid.

to

move

.

is

fanlty.

is

!IO

juice reaching the

inertia

also

flywheel

on

such a starter

Thrn

Hopifi;lly

even

probably

~pe

or

moves.aIl

of

the

engine.

the

starter

it

will

though

the

fanlly.

solenoid.

pre-engaged.

ann

that

Using

will

run

switch

create

enough

confllcts

In

a

the

on

to

inside

En~lne_s.&

Generators

30

DUAL

DESCRIPTION

Dual

output

and

high output alternators

optional equipment

alternators can

add-on

equipment

Dual

alternators can be configured to charge

batteries at the same

charge each set

on

most WES1ERBEKE

be

installed during factory

at

anytime.

time

or,

using

of

batteries separately.

INSTALLATION

If

an

optional dual alternator

simply

follow

the WES1ERBEKE wiring diagram and the

engine installation instructions.

If

the

new

dual alternator the-boat" engine, carefully instructions

1. Disconnect the alternators negative cable

2.

Remove output [positive]

3. Install the

4, Attach a

alternator's output indicated.

below:

the

alternator

cable.

new

alternator.

new

heavy gauge output cable[s]

has

is

being added

follow

and

Do

terminal

disconnect

not reuse.

[s].

are

assembly

a battery selector switch,

already

been

to

the alternator installation

or

Using the

OUTPUT

available

two

an existing "in-

tape off the

engines.

or

banks

factory

from

the battery.

from

cable

sizes

as

These

as

of

TOTACh'~rr..

installed,

the

ALTERNATORS

BATTERY/::;;::::.:::::~

#4

CABLE

TO

BATTERY

{POSITIVE]

SPACER BRACKET

TO

MOUNTING

5. Make certain that the batteries negative post ground cable

to

the engine block is the same heavy gauge

positive cable.

6.

Mount the regulator

a.

Connect the black

alternator.

A

CAUTION:

without

b.

c.

d. The brown wire "keyed ignition"

first

Plug the 2-pin connector into the alternator, make certain

it

is

firmly

The

red

"battery

batteries positive

which actuates

to

a switched [+]12 volt source. Refer

WESTERBEKE

to

a flat surface

wire

00

not

grounding

seated.

sense"

[+J

post [or the positive cable].

the

regulator, this wire must connect

WIRING

in

to

the ground terminal on the

connect the

wire

any

regulator.

should

is

DIAGRAM for the proper

as

a cool

power

be

connected

the

key

to

the

dry

location.

source

to

circuit

the

connection.

Dual

Pulleys

A variety of accessory pulleys for high charging alternators are available from your WESTERBEKE dealer.

powered

and dual

BATTERY

#4

TO

CABLE

TO

BATTERY

1

REGULATOR

{POSITIVE]

DUAL

OUTPUT

[CHARGING

~~~o",.~~?~'~~~:~~

,

~:{WIRE

.

GONNEC",j-HSE

CONNECTS

'OIL

PRESSURE

DUAL

OUTPUT

BUZZER.

[CHARGING

ALTERNATOR

ONE

BATTERY!

/R'TT"~V

TO

PINK

AND

PINK

TO

THE

BLUE

TO

THE

SWI~CH.

ALTERNATOR

TWO

BATTERIES]

2

Engines. & Generators

31

DUAL

OUTPUT

ALTERNATORS

mOUBLESHOOTING

NOTE:

Before

troubleshooting,

belts

are

tight

and

the

batteries

Regulator

The

red must present,

The volts incorrect,

The

blue voltage load/rpm. key

on, 0 volts

KEY

ON • NO

KEY

OFF·

REGULATOR

Terminal/Color

I

Brown

A

Red

S

Orange

F

Blue

All.

Oulpul

Testing

"battery

always

trace

orange

[approximately 1 with

will

BATTERY

sensing" wire A connects

read

battery

the wire

wire S

trace

wire F supplies current

vary

The

readings

should

the

wire

depending

for a bad

with the

VOLTAGE

TEST

POINTS Ignilion o

12.6 o o

12.6

REGULATOR

VOLTAGE

AND Oil

volls

volts volls volts

volts

voltage.

read 0 volts

the

for a bad

on

can

vary

key

off.

REGULATOR

PROPER

Ignition 2 12volls o

10

12

make

certain

that

are

in good

condition.

to

If

battery voltage

connection.

with the

key

on.

If

the readings

connection.

to

the alternator

the battery charge

from

4 to

12

IS

.DEFECTIVE

IS

DEFECTIVE

VOLTAGE

On

Engine

-12

volls

-11volls 4 -12 volls

14.2volls

14.2 6-8

14.2

the

battery,

key

volts

Running

volls

volts

drive

is

not

off,

are

fields,

or

actual

with

12

its

the

Alternator

The regulator is functioning properly are

in

1.

Test the

it

off-key the should

Z.

Hold a

If

.not,

[open

3.

Start the engine,

indicate

.

indic~te

Apply a load should indicates the

Testing

good condition.

voltage

on.

voltage<

read

screw

voltage is

the

problem

circuit].

maintain

The

in

the

present

14.2

the

alternator

at

the

same.

driver

volts

such

alternator

the

voltage

plug

close you

may

be

at

fast

[no·

as

an

at

least

alternator

at

the

[blue

wire

[1/2"]

should

the

brushes

idie

the

load].

A reading

is

not

performing

electric

13.8

volts.

is

faulty.

and

the

batteries

plug

with the engine

alternator tenninal F

F]

from the

to

the

feel

the magnetic

[worn]

regulator

alternator

or

the

pulley.

field.

rotor

output terminals should

of

12.6

would

properly.

bilge

pump,

the

voltage

13

volts orless

and

If

NOTES:

o

When

the

engine

is

first

for

the

is a noticeable

RPM gauge

o A slight

on·

the

ailernator.

alternator

change

will

whine

is

to

"kick in"

excite.

normal

started,

in

the

·sound

when

it

takes

and

take

of

running

a few

the

wad.

the

engine and

with a foil

moments

There

the

load

o

When become

o When

purchase and

the

alternator is

very

hat.

replacing

the

alternator

replace

producing

dual

belts

high

drive

in

amperage,

belts,

always

matched

pairs.

it

will

Engines & Generators

DUAL

OUTPUT

ALTERNATORS

DESCRIPTION

Dual

output

and

high

optional

alternators

add·on Dual

batteries charge

equipment

can

equipment

alternators

at

the

each

set

be

installed

at

can

same

of

batteries

on

be

time

INSTALLATION

If

an

optional installed, and

the

If

the

new the-boat" instructions

1.

Disconnect

simply

engine

dual

engine,

below:

dual

alternator

follow

installation

alternator

carefully

the

alternators

output

alternators

most

WES1ERBEKE

during

anytime.

configured

or,

using a battery

separately.

has

the

WESTERBEKE

instructions.

is

being

follow

factory

to

already

added the

negative

are

available

assembly

charge

two

selector

been

wiring

to

an

alternator

cable

from

BAlMAR

as

engines.

These

or

as

banks

switch,

factory

diagram

existing "in·

and

regulator

the

bat-

REGULATOR

5.

Make-certain that

to positive

6.

Mount a.

of

alternator

A

without

b.

c.

d.

tery.

2.

Remove output

3. Install

4.

Attach a new alternator's

indicated.

LENGTH

~~~~~~~UP~T~O~2~O'~~#O~W~I~RE~

,.

(ALWAYS

the

alternator

[positive]

the

new

alternator.

heavy

output

REQUIRED

USE

FINE

and

cable.

gauge

tenninal

UP

TO

UP

TO

STRAND

disconnect or

Do

not

reuse.

output

[s].

Using

6'

#4

12'

#2

CABLE)

cable[s]

the cable

WIRE WIRE

tape

from

.

#14

BLUE/114

IGNITION

off

8+

the

sizes

PINK

e.

Dual

A

variety charging dealer.

the

engine

block

cable.

the

regulator

Connect

the

black

(ground)

CAUTION:

first

grounding

Plug

the

2-piJf

and

make

certain

The

red "battery

batteries

The which tQ, pressure

positive

brown

wire

actuates

a switched [+]12

switch.

A brown wire the

regolator.

Pulleys

of

accessory

alternators

the

batteries

is

the

to

a flat

wires

00

not

connector

it

is

finnly seated

sense"

[+]

post [or the

"keyed

the

regulator,

volt

from

the

pulleys

are

available

BALMAR

114

negative post ground cable

same heavy

suITace

to

the mounting bolt on the

connect

the

regulator.

into the

gauge

in a

cool

any

power

alternator

as

the

dry

source

connection

wire should be connected

positive

igultion"

this

wire

source. Such

electric tachometer

for high

powered

is

the

cable].

key

must

as

the oil

circuit

connect

connectS

and dual

from your WESTERBEKE

100

AMP

ALTERNATOR

BLACK/GROUND

location.

to

the

to

14

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TO BAmRY USING

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IGNITION·~Bt~·

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,

.#4

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.

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Engines & Generators

~

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STARTING

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#14REO

.

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118BROWN

NDTUSED

/14

WHITE

STATOR

114

BLUE

FJELD

ALTERNATOR

MOUNT

(GROUND)

32A

DUAL

OUTPUT

ALTERNATORS

TROUBLESHOOTING

NOTE:

Before

troubleshooting,

belts

are

tight

and

the batteries

Regulator

The

red must present, trace

The volts [approximately]

incorrect,

The

blue voltage load/rpm. The readings key

on, 0 volts

KEY

ON • NO

KEY

OFF·

REGULATOR

Terminal/Color

I

Brown

A

Red

S

While

F

Blue

All.

Testing

"battery sensing"

always

read

battery

the

wire

white

wire S should

trace

the

wire

wire F supplies current

will

vary

depending

with

the

VOLTAGE

BATTERY

VOLTAGE

TEST

POINTS

•

Ignition Dvolts

12.6

volts

o

volts

Ovolts

Oulpul

12.6

volts

wire

voltage.

for a bad

read 0 volts

with

the

for a bad

on

can

vary

key

off.

REGULATOR

AND

PROPER

Off

Ignlllon

1

2 12

o

volts

10

12

make

certain that

are

in

good

A connects

If

battery

connection.

with

key

on.

If

connection.

to

the alternator

the

battery

from 4 to

IS

DEFECTIVE

IS

VOLTAGE

On

·12

volls

·11

volls

volts

BALMAR

the

drive

condition.

to

the

battery,

voltage

the

charge

12

DEFECTIVE

Engine

14.2

14.2 6·8 4·12volts

14.2

key

off,

readings

fields,

or

volts

Running' volts volts

volts

volls

is

with

it

not

12

are

its

actual

the

REGULATOR

Alternator

The regnlator are in good condition. .

1.

Test off-key on. The the should

2.

Hold a screw

If

not, [open

3.

Start the indicate indicate the alternator

Apply should indicates the

NOTES:

o

When

for

noticeable change

o A slight whine

normaL

Testing

Is

the voltage at

voltage in

read the

voltage

is

the problem

circuit].

engine,

14.2

a load

maintain

the engine

the

alternator

functioning properly and

the

alternator

voltage

at the

the

plug

[blue

wire

same.

driver

close

[1/2"]

present

you

should

may

be

the

brushes

at

fast

idle

the

volts

[no

load]. A reading

is

not

performing

such

as

an

electric bilge pump, the

at

least

13.8

alternator

from

is

faulty.

is

first

started,

to

"kick in" and

in

the

sound

the

alternator

plug

alternator

F]

to

the

feel

output

volts.

13

it takes a

take

of

the

when

the

batteries

with

the

engine

terminal F

from

the

regnlator

alternator

the

magnetic

[worn]

or

the

ternrinals should

of 12.6 would

properly.

voltage

volts or less

lew

moments

the load

engine

the load

fa

J.

and

pulley.

field.

rotor

is

If

o

When

the alternator

become very

o

When

replacing

purchase and

NOTE:

For additional information

alternators, contact www.BALMAR.COM.

hot.

the

replace

is

producing high amperage, it will

alternator

dual belts

drive

belts,

in

matched pairs.

on

regulators and

always

~

WESTERBEKE

Engines & Generators

328

The

following relating lems,

troubleshooting

to

engine

and

the

recommendations

service,

the

probable

table

to

overcome

ENGINE

describes

causes

certain of

these

TROUBLESHOOTING

problems

prob-

problems.

NOTE:

The

ampere

the

back

the

same

engine ~ electrical

manual

of

the

reset

engine.

bracket.

circuit

The

system

breaker

preheat

is

protected by a 20

located

solenoid

on

a bracket at

is

mounted

on

Problem

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

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

1.

Battery

2.

20-amp

3.

Loose

Connection

1. Gear

2.

3.

Faulty Faulty

4.

5.

Loose

6.

Low

1.

Poor

Defective

2.

Faulty

1.

2.

Preheat Faulty

1.

2.

Fuel

1-

Oil

2.

High

Low

3.

4.

Poor

DC

S.

(tachometer DC

1.

2.

Alternator

Probable

switch

not

circuit

breaker

battery

connections.

to

solenoid

shift

not

in

switch. solenoid.

battery

connections.

battery.

connections

fuel

solenoid.

fueling

system.

solenoid

DC

alternator.

run

solenoid

pressure

switch.

resistance

battery

connections.

alternator

charge

not

circuit

drive.

CausD

on.

tripped.

faulty.

neutral.

to

fuel

solenoid.

faulty.

will

not

leak

to

ground.

leak.

charging

operating).

faulty.

de·energize.

1.

Check

2.

Reset

circuit

3.

Check engine

1.

Check

Gear

2.

HURTH

3.

Check Check

4.

Check

5.

6.

Check

1.

Check

2. fuel

Check

1.

1 ••

Check

lb.

Fuel

fuel

Check

2.

Remove

1. Manually

2.

solenoid.

1.

Observe

is

2.

Check lines. after

3.

Check

4.

Check

corrosion

Check

S.

DC

Pertorm

1.

Tesllng

2.

Check

for

volts

VerlllcalionJRemedy

switch

and/or

battery

breaker;

if

and

connection.

shift

run

filters

system.

not

short

ELECTRICAL

loose

are

breaker

check

circuit

(+)

connection

ground

stud.

Check

must

be

HSW

switch that

battery battery

connections.

that

solenoid.

that for

solenoid.

running.

wiring.

(Do

all cable

connections,

the

drive

In

TRANSMISSIONS).

with

ohmmeter.

12

volts

are connections. charge

12

volts

are

fuel

valves

air

in

fuel

system.

clogged.

Replace

Exc.

connection

disconnect

if

gauges

and

Testtha

Insert

not

wires

DC

connections.

present

sensitive

start

engine.)

is

located.

for

temperature

connections

check

SYSTEM/ALTERNATOR.

voltage

check

BatteI)'

Charging

belt

tension;

at

the

trips

for

shorts

to

starter

battery

neutral

present

state.

present

are

open.

at

the

12

panel

oil

pressure

at

belt

alternator

Check

Exc.

connections.

again,

check

to

ground.

solenoid

cable

(see

NEUTRAL

at

the

solenoid

althe

(+)

Bleed

air

from

filters

and

bleed

alternator;

volt

Remove

battery

of

connection

lights

are

switch.

(0 -.25

connections

rise

to

for

tension,

generator

Circuit.

should

output

with

terminal.

repair

activated

amp)

locate

loose

preheat

solenoid

and

(-)

connection

connections.

SWITCH

connection.

connection

fuel

system.

air

from

alternator.

to

the

fuel

when

rneter

in

and

the

fault.

connections,

test

alternator.

charging

Circuit.

turn

freely.

voltmeter.

under

on

the

run

engine

battery

replace

See

Check

Ensure

to

12

-.¥

WESTERBEKE

Engines & Generators

33

(continued)

ENGINE

TROUBLESHOOTING

Problem

Engine

slows

and

stops,

Engine

overheal5/a~rm

Engine

alarm

sound

,

Exhaust

smoke

problems

sounds

pulsates.

steadY,

Probable

Fuellift

1.

2.

Switches

or

disconnected.

3.

Fuel

starvation.

4.

20

Amp

Exhaust

5.

6.

Water

7.

Air

intake

1.

Raw

water

2.

Coolant

1.

Loss

of

Oil

pressure

2.

Engine

3.

4.

High

temperature

too

Iowa

Bluesmoke.

1.

White

2.

Black

3.

Cause

pump

failure,

and/or

wiring

circuit

breaker

system

is

in

fuel.

obstruction.

not

circulating.

not

circulating.

oil.

switch,

coolant.

temperature.

smoke.

smoke,

loose

tripping.

restricted.

switch

opens

at.

Verification/Rumedy

1.

Fueilift

pump

2,

Inspect

3.

Check

4.

Ensure

cause Check

5.

exhaust

6.

Pump bleed

7.

Check

Raw

1.

Obstruction

2. 2

••

Thermostat -remove

Replace

2b.

Loss

for

leaks.

2

••

Broken

2d.

Air

leak

bleed

Check

1.

oil

drain

Replace

2.

3.

Check Check

4.

check

1.

Incorrect

la.

Crankcase

through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel

insufficient

exhaust

3b.lmproperly

3

••

Lack

ventilation.

3d.

Overload.

should

with

spare,

wiring

for

switches

fuel

supply,

for

high

breaker

tripping.

for

blockage,

elbow.

water

from

fuel

system.

air

intake

water

pump

at

thermostat.

of

coolant -check

or

loose

in

system;

air.

Add

dipstick,

hose

oil

pressure engine for

satisfactory

with

ohmmeter,

grade

is

overtilled

the

exhaust).

is

running

injector

grada

bum

incomplete

air

system;

timed

of

air -check

make a distinct

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

fuel

tank(s);

filter

cartridge.

failure.

Check

raw

water

intake

and

hoses,

belts

-tighten/replace.

run

engine

coolant

as

needed.

look

for

oil

connection.

switch.

coolant

level.

operation

replace

of

engine

oil

with

cold.

or

incorrect

of

fuel,

due

proper

check

air

injectors

air

to

combustion

intake),

intake

for

ticking

and

loose

operation.

and

draw

sensitive

hose,

change

impeller -replace.

test

and

leaks

if

. .

engine

injector

high

or

valves,

and

connections.

fuel

filters.

during

operation.

to

heat

carbon

filters

or

raw

water

in

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

by

the

step

is

and

the Negative

Assuming instrument panel

1.

Disconnect gauge

situation.

2.

Remove sender and full

reading

gauge

when

to check

that

reads

the

scale,

the

for

(B-)

there

energized

the

sender

zero,

wire

connect

which

is other

instrument

12

volts

terminals

is

12

which

attached

it

is

the

than

what

is

panel

is

DC

between the ignition (B+)

of

the

gauge.

volts

as

required,

and

perform the

wire

at

the

gauge and

is

the

normal

to

the

sender tenninal

to

ground.

normal

See

reading

COOLANT

TEMPERATURE

normally indicated

energized,

leave

following

reading for

if

the

for

the

see

gauge

this

'WIY'

the

first

steps:

if

the

this

at

the

reads

situation.

WESTERBEKE

Engines & Generators

AND

If

both

of

the

undoubtedly

conductor

If

either of the above

probably

defective and

Assuming

sender

to

the sender tenninal

Check

that

Some

starters have isolated ground'tenninals

battery

is

connected to tenninals), the ground to

the

block.

34

OIL

PRESSURE

above

OK

and

from

the

the gauge

the

engine

gauge

the

sender

gauge

should

is

OK,

block

the

side

GAUGES

tests are

problem

to

the

gauge

tests

are

be

replaced.

check

at

the gauge

is

connected

starter (both

will

not

positive,

lies

either

or

negative,

the

conductor

to

plus

necessarily

the

with

the

for

continuity.

the

ground.

and

be

gauge is

the

sender.

gauge

from

the

if

the

minus

connected

is

DRIVE

Proper is

Drive

will eventually

tight

alternator tension service life of the coolant

presence of

in The

no (12mm) point A

Adjusting

I,

2.

3. Pivot

4.

BELT

inspection,

important

Belts

belts

must

not

provide

damage

will

pull

to

can

high

operating

drive

belt

less

than

as

the belt

between

spare

belt or belts

A

WARNING:

drive

belt's

Loosen mounting

With

the

edges.

the

or right Tighten

bolt.

5.

Run

the

recheck

RAW

WATER

The

tension releasing and checked

forth.

the

The water

often.

ADJUSTMENT

service

for

the

efficient

under MAINTENANCE

be

properly

proper

the

alternator.

the

alternator

wear out

also

oil

3/8

prematurely.

cause

rapid

on

the belt

temperatures

is

properly

inch

(lOmm)

is

depressed

the

two

should

pulleys

Never

tension

Belt

the alternator adjusting strap bolt

belt

alternator

as the

engine for

the belt

TenSion

bolt.

loose,

required,

base

mounting

tensions.

while

inspect

PUMP

of

the

raw

pumps

fasteners

pump

NOTE:

WESTERBEKE

be

ments

below

is

provided

and

maintenance of the drive

operation of

SCHEDULE).

tensioned.

alternator

out of alignment

wear

pumps

can

cause belt

and tachometer

adjusted

and

on

always

attempt

the

engine

for

on

the

base mounting bolt

to

loosen

bolt

about

5 minutes,

water

pump belt is

and

belt should be

Loose charging Drive belts that

Excessive

of the belt and

bearing. A

if

the belt

no

more

with the

the longest

be carried

to

check

is

wear,

cracks

or tighten.

and the

Sliding

ENGINE

peiformed by a competent

to

your

engine

drive

and

will

are

and/or

drive

reduce

slack

belt or the

slipping,

variations.

can

be

than

112

thumb

at

span

On

board.

or

adjust

in

operation.

and

the

and

frayed

adjusting

then

shut

adjusted

the

pump

finnly

tight

ADJUSTMENTS

recommends

assist

the

mechanic.

belts

(see

belts

too

cause

the

belt

tlJe

resulting

deflected

inch

the

mid-

of the

belt.

the

base

to

the

left

strap

down

and

by

back

and

that

the

following

engine

mechanic.

10

case of

severe

of

positive

injector

room

as a spare

removing

of

the

down

easily

injector

it,

and

This

overhaul

checked

service

faults.

environment,

injector

into

and

side-to-side

then

seats

washer

with a uew

injectors

injection loss in clean injector

Before base falling out the free

The injector washer. replaced

installed. The fuel injectors

hours,

engine

ad' 'st-

The

infO!

vibrations

and

center.

fuel

Since

should a problem

the

to

the

is

held in by carbon build-up

lift it

in

should

if

needed.

and detonation

overhauled

Poor

pressure

fuel injectors must be serviced in a

it

old

injector,

help

injector

with

out.

the

cylinder head should be removed with washer

be

by

fuel

quality,

to

the injection

is

best

prevent

hole.

the

aid

when

pop

tested after

55:

FOUR

1850

TO

an authorized

to

carry

occur.

clean the area

any

If

the injector will

of

the

INJECTION

1990

noise,

have the

fuel

contaminant's and

pump

can result

at

least one extra

around

rust or

debris

or

the

like, work

the socket

on a copper

new

-..

PSI

wrench

the

injector and

injector is

750

operating

STARTING

(12.7T0

13.7MPA)

sealing

the

from

not

lift

to

PRESSURE

STARTER

The maintained following

manual.

Major service/overhaul of

alternator should be undertaken

. Refer

starter

to

your

AND

DC

ALTERNATOR

and the

DC

charging

the

WESTERBEKE SERVICE

alternator

maintenance

the

starter or

as

SERVICE

schedule

DC

needed.

MANUAL.

should

in

charging

be

this

,.y:

WESTERBEKE

EnQjns.~

35

.

RAW

WATER

& Generators

PUMP

NOTE:

ments

be

below

is

ENGINE

WESTERBEKE

peiformed by a

provided

to

assist

ADJUSTMENTS

recommends

competent

the

that engine

mechanic.

the

following

mechanic.

engine

The

information

adjust-

TESTING

Make

certain

and

the

air

must

also

be

1.

Wann

the engine

2.

Disconnect

-

3.

Remove the

compression gauge/adapter

cylinder

4.

Close

the raw water seacock

5.

Crank

the engine

maximum

6.

Repeat

NOTE:

If

the

an

overhaul.

ENGINE

intake

on

this

COMPRESSION

the

oil

level

filter

in

good

condition. to

the

wire

all

the

glow

which

and

reading,

process

readings

(dipstick)

is

clean. The

normal

to

the

plugs

the

compression

allow the

then

record that

for

each

are

below

is

at

the

correct level

battery

and

operating temperature.

fuel

shutdown

from

the

combination

~FUEL

{/!

/1

SOLENOID

(thru-hull).

gauge

cylinder.

the

limit,

solenoid.

engine

is

to

be

measured.

SHUTDOWN

to

reach a

reading.

the

engine

starter

motor

and install

to the

needs

OIL

PRESSURE

The

engine's

by

the

oil pressure

normal

operation,

85

psi.

NOTE:

A

reading

.

pressure depending

Low

Oil

The

specified

gradual

For

additional

the

ENGINE

Testing

To

test

oil

install

a mechanical warming the

oil

pressure

oil

pressure, during operation,

gauge

on

the

oil pressure will

newly

up

to

reading

upon

started,

85

cold

psi. A warmed

as

low

as

25

the

temperature

Pressure

safe minimum oil pressure

loss

of oil

pressure

information

TROUBLESHOOTING

Oil

Pressure

pressure, remove

up

the

engine, set

gauge.

55'

FOUR

43

TO

85

PSI

.

usually indicates

on

oil

pressure gauge in

OIL

PRESSURE

(290

TO

is

indicated

the

instrument panel. During

range

between

engine

can

have

an

engine

can

have

psi.

These

readings

of

the

engine

and

is

5 - 10 psi. A

worn

low

oil

pressure

chatt.

the

oil pressure sender then

the

engine speed

590

KPa)

NORMAL

readings,

its

place. After

at

idle and

40

and

oil pressure

an

oil

will

vary

the

rpms.

bearings.

see

read

55' 441 SPEED

44.1

7. Re-install the the

threads) and

S.

Open

the

i

Low

Compression

When

low

compression applying plug

Install compression reading rings. with

A

both

a small

hole.

Allow the

the

pressure

If

the compression valve

the

valves.

slight

rise in compression would

the

rings and

MEASURING COMPRESSION

FOUR

COMPRESSION

PSI

(3.04

MPa)

OF

250

RPM.

PSI

BETWEEN

glow

plugs

reset

raw

water seacock (thru-hull).

is

amount

oil

gauge

rises

the

valves.

of oil

to

PRESSURE

NORMAL

CYLINDERS

(use

anti-seize

the fuel shut-off

found,

determine

in

the

settle.

and repeat

dramatically,

does

COMPRESSiON

~

AT

CRANKING

cylinder

the

above

the

not

rise,

indicate

compound on

to

the rnn

the

fault

the problem

a problem

cause

thru the

test.

If

is

with

GAUGE

position.

by

glow

the

with

is

MECHANiCAL OIL

PRESSURE

GAUGE

. .

'~

.~

~.

OIL

PRESSURE

SWITCH'

~

WESTERBEKE

.

En~ines & ~enerators

36

VALVE

The hours Valve

. Cold

NOTE:

to clearances.

CLEARANCE

valve

clearance

or whenever

adjustment should

engine

The

Cylinder

"Angular

TIghtening

retighten

valve

the

cylinder head bolts before adjusting

ADJUSTMENT

NOTE:

competent engine assist

ADJUSTMENT

must

be

adjusted every

the

valve

rocker

is

only

be

done

clearance

heGd

is

0.015in

bolts have been tightened with the '

MetTwd".

Therefore,

PROCEDURE

f

ENGINE

The

following engine

the

mechanic.

500

operating

abnormally

when engine is

(0.40mm).

VALVE

CLEARANCE

it

is

not necessary

CRANK

PULLEY

mecTwnic.

noisy.

cold.

the

valve '

ADJUSTMENTS

adjustments

The

sTwuld

be

peiformed by a

information below

3. In accordance with

sure marked

Valve ,arra.ngemant

When

'

No.1

in

the compression stroke

When

No.4

in

the cotnpression stroke

4.

On completion of the valve clearance alignment make a mark alignment

in

the

clearance of the other

A

aluminum.

adjusting

Adjustment

The

injection timing

forget

to

reassembling

is

provided

and

adjust

if

required

with either@

Cylinder

normal direction.

No.

cylinder is at

I:

as

CAUTION:

Therefore,

screw

of

Injection

insert a shim

the

injection pump after disassembly.

tlJe

Inlet E .. Exhaust

in 1

The to

excess.

may

in

to

ccmditions

or.

TDC

TOC

by

Then

valves.

rocker

be

of

cylinder No.1, mea-

the

clearance of the valves

in

the

table

below.

1 2 3

I E I E I

•

giving a turn

measure

arm

careful

is

made

not

and

Timing

not

be

re-adjusted. Take care not

the

mounting surface when

E

•

©

I1il

to

the crankshaft

adjust

of

die-cast

to

tighten

I

© ©

the

4

E

to

. - -

1.

Tum

the

crankshaft clockwise

the crank pulley

the

timing gear case cover. i

on

2. Remove der in the exhaust stroke. When

are closed, stroke,

IDC

CYLINDER COMPRESSION·

the

No.1

is at

and

in the exhaust stroke.

NO.1

-';

is

cylinder head cover

IDC

the

cylinder

when

~

-

so

that

aligned with the TDC mark (cast out)

and

check

in

the

compression stroke or at

the

intake

is

at

IDC

in

the compression

only

the

exhaust valve is open, it

-

~l-J--

....._"'57\ ;

r

---' \ ",,--,

"."\

the

mark groove on '

to

see

imd

exhaust valves

7\

. G

CYLINDER EXHAUST

...

NO.1,

if

cylin-

IDC

is

_~

,

.

at

IDLE

SPEED

(OPERATING

Engine idles speed (All

models Idle speed operating temperature

Cruise RPM

Models Model 55DIFour

Maximnm RPM (propeller loaded) Models

Model 55DIFour 2550-2600

RPMS)

in

this

should

55BIFour

manual)

be

adjusted

and

with

the engine in

range.

55CIFour

55C/Four 2950-3000

950 -

1000

2000-2500 2000-2400

rpm its

rpm rpm

normal

~

WESTERBEKE

Engines & Genera/ors

37

DESCRIPTION

The infonnation Transmissions,

SECTION

CONNECTION

HBW

recommend a flexible mission flexibly deflections. ing the

SPECIFICATIONS

shaft care using a universal manufacturers

Even coupling

bo~

boats

flange

gearbox

mounted,

is

not

transmission

should

with

bearings

or

where

and

below

the

TRANSMISSION

applies

to

OF

and

in

The installation of a

required,

bearing,

be protected

be

taken

joint

instructions.

the

engine

or'

;;PRIVESA

caused

the

distance

stem gland

is

specific

an

models.

GEAR

the

propener

order

to

since

the

provided

is

not

exceeded.

from

to

prevent

shaft,

solidly

VER"

by

hun

is

less

ZF

MARINE

to

the

HBW

TROUBLESHOOTING

BOX

WITH

PROPELLER

connection

compensate

special

propener thrust

additional

torsional

make

mounted,

wiJI

distortions,

between transmission output

than

between the

shaft

if

the engine

for

propener thrust

the value

However,

loads.

vibration.

certain

to

the

reduce

stress

especially in

about

32

angular

will

be

specified

the output

Special

observe the

use

of a

in the

in

(812

HURTH

transis

taken

under

When

flexible

gear-

wooden

mm).

HBW

TRANSMISSIONS

NOTE:

When

installing

bear-

by

shifting is

Bowden sheaves, support for threaded

gear

CONTROL

The Upon

be

elements

actuating

plate:

be'O.5mm.

The

actuating

tion

coincide The shifting

actuating

positions A

point

A greater

detrimental

travel

which,

generation

by

NOTE

season.

LEVER

CHECK FROM FORWARD

not

impeded

cable

or

too

small a bending

shift

holes

hausing.

Refer

CABLES

transmission

loosening

moved

to

any

(cable

lever

the

minimum

control of

slow

FOR

NEUTRAL

cable

lever

the

shift

with

the

travel,

lever,

and

30mm amount

and

is

shorter,

in

tum,

and

clutch

Checkfor proper

TRAVEL

EQUAL

TRAVEL

THRU

AND

REVERSE.

rod

linkage,

control

located

to

is

suitable for

the

retaining

position

or

rod

does

not contact

distance

should

when

in

operating lever

neutral

as

between

B should

for the inner

of

shift lever

is

recommended.

proper

would

clutch

engagement

FORWARD

8,

the

transmission,

by

restricted

by

radius,

cable

connections,

above

the

WESTERBEKE

single

screw,

required

linkage).

the

l)etween

be

arranged

the

neutral

on

position

measured

the

neutral

be

at

least

pivot

travel

clutch

engagement

mean

premature

plate

failure.

or

no

actuating

make

movability

unsuitably

etc.

In

shift

cover

lever

the actuating

for

the

Make

certain that

actuating

lever

at a right

position.

the

control

of

the

actuating

at

the

pivot point of position 35mm point.

is

in

However,

wear,

This

would

engagement

lever

travel

certain

that

of

the

positioned

order

use

on

parts

remote

shift

control

lever

and

The

console

and

for

the

no

way

if

the

might be impeded

excessive

at

to

the

top

list.

lever

the

cover

angle

neutral

lever.

end

outer

lever

be

indicated

all.

least

guide

mount

two

of

the

control.

can

cover

should

to

the

posi-

should

the

pivot

heat

each

a

HURTH

COblER

A

CAUTION:

the

actuating

shift

lever

this

mechanism

transmission

*"DRIVESAVER"

The

position

lever

is

travel

from

is

In

any

warranty

is

a product of Globe Marine, Rockland,

of

the

mechanism

fa&tory-adjusfed

neutral

position A and

way

tampered

will

be

void.

HBW

to

ensure

with,

behind

equal

B.

If

the

-...v-

,SHIFT~::aj))z""m1~~~"'''''(-....,t.Oi'

CABLE

ACTUATING LEVER

ACTUATING

,COVER

MA.

WESTERSEKE

Engines & Generators

LEVER

PLATE

FLUID

no,,';--

ACTUATING LEVER

~~

0.02

in

MINIMUM

COVER

(0.5mm)

CLEARANCE

38

ZF

MARINE

TRANSMISSIONS

..

~

-"

INITIAL

All with reasons the

Fill

(DEXTRON III). The mark dipstick,

after

sealing ring under the hexhead leaks and

OPERATION

HBW

marine

transmissions

the

engine

at

the

factory

fluid

is

drained

the

gearbox with Automatic Transmission Fluid

fluid

on

the dipstick.

do

not

the

fluid

and

make a visual

hoses,

and shift

I

,

CHECKING

I

screw

level

To

it

is

checked

cables.

are test-run

prior

to

delivery.

before shipment.

level should be

check the

in.

inspection

fluid

Screw the dipstick into the case

and tighten.

of

the dipstick. Check for

of

the coupling,

on

a test stand

For safety

up

to

the index

level, just insert the

Do

not

forget the

oil

cooler

FLUID

LEVEL

. i

FLUID

111~I~ml

FLUID

DRAIN

~~

FLUID

Change the operation, then every 300 operating hours or at least once a year or at winterizing.

Removing

Push a suction the bottom allows, from the bottom dralo into a contalner, then reinstall the plug with its sealing washer. the used recheck the

CHANGE

fluid

for

the

first

time after about 25 hours

the

fluid

pump

hose down through the dipstick hole

of

the housing and suck out the

use the transmission drain). Remove the dralo plug

of

the transmission and allow the

Wipe down

fluid.

DRAIN

PLUG

NOTE:

When

drain

plug

this sealing

A

WARNING:

engine

is

stick

hole.

fluid

TORQUE

sealing

washel:

running.

the

After

running

level

20 -25

changing

washer.

Never

Hot

This

could

transmission and properly dispose of

the engine, shut down and

Mhs

the

fluid,

take

care

The

drain plug

pullout

fluid

cause

the

wilt

splash

severe

dipstick

burns.

fluid.

not

will

from

(If

to

lose

leak

while the

of

space

fluid

the

without

the

dip·

to

OPERATING

'rhe

·maximum

230'

(110'). This temperature can.only

time.

A

too

high,

transmission

LOCKING

Locking of required: tion of travel for position corresponding

WHEN

Rotation is

being operation of the engine charging the battery), will have transmission

DAILY

o Check the transmission o

Visually

transmission.

o Start

idle

o Shift into

NOTE:

from

the

idle

For additional information refer Transmission Section:

NANCE

General

Gear

Note:

of

gear

Only a few

Lubricating

Propeller Direction

TEMPERATURE

permissible

CAUTION:

stop

If

the

fluid.

THE

PROPELLER

the

propeller shaft

use

the gear shift lever position opposite your direc-

this

UNDER

sailed,

SAIL

of

the propeller without load, such as

being

A'f.F

the.

transmission

engine

immediately

purpose. Never put the gear shift

to

the direction

OR

BEING

towed,

or anchored in a

with

the

OPERATION

fluid.

check the gear shift level linkage

the

eugine in

to

warm

gear.

Too

Iowan idle

transmission gear

speed

should

AND

TRANSMISSION

ZF

TRANSMISSIONS

Ratio

(optional)

There

are a variety

ratios

available.

are

listed.

Fluid

Shall 01

Rotation

the

neutral,

fluid.

speed

be

increased

SHAFT

(ZF

and

Standard hardened servo·operated

ZF

15MA

ZF

10MA

ZF

12MA

ZF

15MIV

ATF -type A or·

Right-hand

iisted:

temperature should not exceed

be

reached for a short

fluid

by

an

additional brake

temperature

and

check

of

travel of the boat.

the

is

not

in

TOWED

when

the boat

river,

as

well as

propeller stopped (for

no

detrimental

allowing a

will

produce a

damper plate.

to

the following text in this

COUPliNGS,

TROUBLESHOOTING.

SPECIFICATIONS

Transmission)

helical

(1.88:1

(1.79:1)

(2.63:1)

(2.13:1

rotation

effects

and

few

minutes at

chattering

In

MAINTE-

gears,

with

multiple

disc

or

2.63:1)

or

2.72:1)

Dextron -II

for

above

such

Case

a

clutch

or

III

models

on

noise

cases

the

Engines.& Generators

39

ZF

MARINE

TRANSMISSIONS

OPERATING

A

CAUTION:

too

high,

transmission

Nonnal should A

maximum

reached Make

certaIn

to

provide

TRANSMISSION

Transmission ZFI2M(HBWI24), ZFI5M(HBWI50), ZFI5MA(HBWI50A), ZF25M(HBW250). ZF50.

The

cooler prevents fluid.

However,

will,

in

leaks.

A

transmission

some

circumstances,

waters, WESTERBEKE

TRANSMISSION

TEMPERATURE

If

the

transmission

stop

the

engine

immediately

"uid.

operating

be

for

temperature of the

in

the

range

temperature

a short

time.

there

is

good

ventilation

of 122' F (50' C)

of 266' F (130' C)

enough

space

and

COOLER

coolers

is

a separate part of

any

possibilities of coolant diluting

time,

erode

maintenance,

COOLER

are

standard

ZFI5MIV(HBWI50V)

No

cooler

is

the

continued

the

cooler

depending

etc.

recommends having a

flow

inside of

may

last

it

might only last half

cooling.

needed

the

ten

on

TRANSMISSION

"uid

temperature

and

check

transmission

to

212' F (100'

may

be

around

the

transmission

on

ZFIOM(HBWIOO),

and

for

the

ZF35

transmission of

coolant

cooler

years

operating

spare

the

causing

or

more

which

transmission

thru

but,

hours,

that

cooler

the

fluid

only

the

or

the

cooler

external

in

tropical

time.

aboard.

is

C).

the

MAINTENANCE

Transmission

housing routine 25

hour

least

once

Periodically

and

corrosion. checking (fluid

Lay-up/Winterize

Storage

o

Drain

with

NOTE:

engine

o Clean

(use

o Fill

prevent

months

o Loosen

flange

removing

and

o Inspect

Look for the. all

NOTE:

(twelve months

fluid

before putting

For

additional

maintenance

clean,

check

the

per

operational

break-in

a

seaSOD.

inspect

Make

the

fluid

will

appear

requires

water

a proper

This

raw water cooling system

up

the

heat

resistant

the

transmission

internal or

more).

attaching

and

the

spray

with

the

corrosion

conduit,

moving

If

the

to

prevent internal

ZF Industries

3131

SW

Fort

Lauderdale,

Tel.:

(954)

checks.

and

then

the

transmission

certain

level

look

as

strawberry

special

care. Follow

from

the

mixture

operation

transmission

paint).

corrosion

hardware

propeller shaft

boat

from

lubricant.

gear

shift

of

and

bending

parts.

transmission

or

more),

the

engine back

information

42nd

Street

FL 33312

581-4040

is

minimal.

fluid

level

at

300

the

for

transmission

of

antifreeze

will normally occur when

and

with

Dextron

(extended

coupling

the

cable,

the

end

of

is it should

corrosion.

contact:

Keep

as

part of your regular

Change

the

hours

of operation

and

the

air

vent

is

signs

of

water

cream).

these

oil

cooler

coolant.

is

properly winterized.

touch

up

III ATF fluid to

storage

from

the

transmission

flange

water.

Separate

liokage,

the

to

and

fitrings,

actuator

be

stored for a

be Reduce

into

service.

the

fluid

after initial

cooler

clear and

contamination

procedures:

unpainted

before

the

attachments.

cracks

rods.

topped

the fluid

exterior

or

at

for

when

and

replace

the

areas

only,

twelve

output

flanges

or

cuts

Lubricate

long

off

with

leaks

in

time

level

Engines & Generators

40

CONTROL

The improper problems rather

HURTH

cable

If

you

shut level, the

full tral, observe is

stiff

try

and excessively

CABLES,

majority

the

into

of

clutch

with

than

from

clutches,

adjustments,

experience

engine

then

have a

range -from

full

reverse,

the

actuating

to

operate,

again,

tight

transmission

adjustments

control

problems

in

particular,

operating

down,

helper

and

lever

break

If

it

is

still

bends,

TRANSMISSION

cables

with

First

move

neutral

back

on

the

stiff,

and

difficulties

(manual

(hydraulic

the

are

problems

check

the

to

the

cable

check

arise

as

a result of

transmissions)

transmission itself,

very

sensitive

with

to

the

transmission,

the transmission-fluid

cockpit

full

neutral -

transmission,

shift

forward,

lever

back

while

If

you the

loose at the transmission

the cable for kinks

any

linkage for

binding,

TROUBLESHOOTING

A

new

'cable

and

perhaps a new

.

or

improper

through

to

neu-

remote

or

needed,

out

make

If

have the,propeller needs thrust, the

it

NOTE:

immediately

authorized

While

of'

gear

sure there's

the

transmission

a helper

professional

check

shaft

1

isn

t

stuck

If

you

using

or,

if

marine

the

cable

the

no

passes

put

it

in

shaft;

if the

attention,

to

see

you

have a folcling

in

the

"no

suspect

contact

transmission

is

lever

bincling

forward

shaft

still

pitch"

a major

your

[IZF~

linkage

mechanism

loose,

shift

the

transmission in

on

the

side

of

the

trarisrriissiori

inside

the

case,

these

tests,

crank

the engine and

and

reverse

while

isn't

tuming,

If it

does

have a propeller

or

position.

problem

WESTERBEKE

facility,

the transmission

tum

but there's

feathering

in

your

dealer

on

transmission,

may be

and to

you

observe

no

the end of

propeller, that

or

an

.

Problem

Transmission

Fails

Transmission

fails

Delay

only

Transmission

Chattering

mainly

Boat

Oil

Leakage,

to

move

to

propel

of

gear

after

an

increase

transmission

at

low

fails

to

attain

gears into-gear.

shifts

the

engagement

noise

engine

caimot

into

gear,

boat.

in

speed.

becomes

nOise,

speed,

specified

be

shifted.

but

or

engages

louder.

max,

speed,

Probable

1,

Actuating

2,

Shifiing

unattaChed,

3,

Actuating

.cover

plate

1,

Output

2,

Propeller

Output

3,

Output propeller

1,

Actuating

equal

to

2,

Actuating

3,

Actuating

1,

Damage to

wear

ment

between

2,

Beginning

mission

without

transmission,

1,

The

engine

vibrations

a

"chattering"

1,

Operating

2,

Operating

1,

CorrOSion

Damagg

2,

Misalignment

lever

is

cable

is

Cable

lever

is

. .

coupling

shafi

is

coupling

shaft

are

lever

travel N to B not,

N

to

A,

lever

travel

lever

is

starting

or

fatigue,

engine

damage

due

to

torsional

fluid,

overload,

or

propeller

in

the

noise

temperature without

at

radial

sealing

of

Cause

loose.

broken,

bent

redius

Is

binding

against

"

is

not

turning,

not

turning,

is

turning,

and

turning,

is

insufficient.

binding

against

on

flexible

possibly

and

transmission.

of

bearings

vibrations,

wrong

excessive

generates

drive

unit

which

in

the

transmission.

Is

high,

cooling,

sealing

ring, output

flanges,

or

too

severe,

the,

cover

plate,

coupling

due

to

misalign-

in

trans~

running

alignment

en~ine

output.

torsional

produces

ring

and

shaft.

1,

2,

3,

1,

2,

3,

1,

2,

3,

1,

2,

of

1.

2,

1,

2,

1.

2,

Verilicaiion/Remedy

lighten

damping

Check

the

cable,

Detach

the

hand,

Transmission

The on pins

Inspect A propeller

Adjust See

Check

DIAGRAM,

Check Check

inspect

engine.

Transmission

Mount a flexible

between

a

Inspect

transmission.

Wrong Check

Transmission

Check

shift

Clearance

coupling

the

propeller

and

coupling

the

folding

propeller;

propeller

may

cover

plate

ACTUATING

shift

lever

clearance, alignment,

the

damper

Replace

the

higher

engine

stiffness

the

damper

type

of

cooler,

alignment.

needs

bolts

be

needs

Replace

fluid,

Inspect

needs

bolt

on

actuating

reattach

or

replace,

cable

and

operate

should

beO,02

in

professional

are

sheared

shaft

lighten

bolts

it

may

in

"no

until

LEVER

cable

adjust

inspect

plate

if

necessary.

professional

coupling

and

factor

plate

Use

coolant

professional

Must

attention.

or

as

necessary,

may

be

missing

be

jammed, A variable

pitch",

position,

the

lever

is

TExr

AND

length,

See

if

necessary,

flexible

between

with

another

transmission; a coupling

might

be

between

if

necessary.

ATF

Dextron

hoses

be

within

lever,

the

actuating

(0,5mm),

the

coupling

rep~ce

set

screws,

or

damaged,

exact

mid-position,

DIAGRAM,

ACTUATING

coupling,

If

the

attention.

sufficient.

the

attention.

0,003

noise

transmission

stiffness

engine

and

III,

check

and

coolant

in

(O,OBmm),

lever

by

is

slipping

keys,

pitch

LEVER

perSists,

and

factor

with

the

fluid

level.

flow,

the

Engines & Generators

41

TRANSMISSION

.TROU_~LESHOOTINGJZFt

Chattering

mainly

Transmission

fails

NOTE:

transmission

at

low

to

propel

Tf

you immediately authorized

Problem

speed.

into

boat.

noise,

gear,

engine

shifts

the

suspect a major

contact

marine

your

transmission

1.

2.

but

problem

1.

2.

3.

in

WESTERBEKE

facility.

Probable

The

engine

vibrations

a

Damper

Output Propeller

Output

propeller

in

"chattering"

plate

coupling

shaft

coupling

shaft

your

transmission,

dealer

or

Cause

or

propeller

the

drive

noise

chatter.

is

and

are

an

generates

unit

in

the

not

turning.

not

turning.

torsional

which

produces

transmission.

.

1.

Mount a flexible between a

higher

2.

Advance should

2a.

1.

2.

3.

be

If

chatter

Transmission

The

coupling

on

the

propeller

pins

and

Inspect A

folding

Variable

-Verlilcallon!Remedy

coupling

with

the

engine

stiffness

throttle

slightly,

adjusted.

continues,

needs

bolts

shaft.

coupling

the

propeller;

propeller

pitch

propeller

and

factor

inspect

are

bolts

may

another transmission; a coupting might

be

sufficient.

if

chatter

the

damper

professional

sheared

TIghten

it

or

as

necessary.

may

be

missing

be

jammed.

may

be

in

attention.

replace

.'

stops

the

coupling

"no

stiffness

the

idle

plate.

set

screws,

or

damaged.

pitch"

position.

factor

with

speed

is

slipping

keys,

~

WESTERBEKE

Engines & Generators

42

BORG

WARNER

VELVET

OPTIONAL

DRIVE

TRANSMISSION

SHIFT

The the

(Fl, Neutral (N),

ball to the actuating

•

improperly the actuating ensure

TRANSMISSION

LEVER

gear shift

actuating lever

located

center the lever

helm

transmission.

proper

behind

must

lever

adjusted

lever

control

be

through

should

operation.

POSITION

mechanism

on

the transmission exactly in

and

Reverse

the

transmission

in

each

coordinated

shift

mechanism

The

shifting

be

free

(R)

position.

with

mechanism

mechanism of dirt

and

linkage must

shifting

lever

The

those

can

and

position

Forward

positions. A detent

must work

gear

shift

of the

adjustments. An

cause

and transmission

well

freely

positions

Velvet

Drive

damage

lubricated

at

to

FROM

COOLER

CONNECTION

SHIPMENT

For

safety

reasons, the transmission fluid is

temporarily attached

Before leaving the undergoes a test fluid.

The residual fluid remaiuing

acts

draining against corrosion for at least

as

TRANSMISSION

Check the transmission fluid transmission continue operation, output shaft changed 300 operating

A

and starting

has

to

use

keep

and

after

the first

hours

CAUTION:

the

correct

the

engine.

transmission

during

shipment

to

the

WESTERBEKE

run,

with

Dextron

a preservative

FLUID

not been

tltis

a lookout for

transmission

Be

size

filled,

fluid.

During

25

hours

thereafter

certain

cooler

is

not filled

and

the selector lever

actuating

and

one

level

any

cooler.

andlor

the is

shaft.

plant, III ATF transmission in

the transmission after

provides

year

if

properly

on

the

dipstick.

fill

with

Dextron

the

first

25

leakage

and

transmission

properly

at

This fluid should be

approximately

at

winter lay-up.

installed

WARNER

VELVET

DRIVE

TRANSMISSION

with

each transmission

protection

stored.

If

the

III and

hours

of

the

bell housing,

every

is

filled

before

Shifting

Place Shifting tion

order. speed. allow

Into

the gear shift

from

may

be

Shifts

Start

the

transmission

Neutral

Move

the gear

feel

the

detent. mission. completely sion

NOTE:

switch.

aligned

does

Some

Unless

With

not

in

Forward

Move

the gear shift

feel

the

detent. The

the

forward

move

the boat

Reverse

Move

the gear shift

feel

the

detent. The

the

reverse

should

move

NOTE:

Moving Position always

the engine! of

to

away

gear shift

This

the

actuating

Gear

in

one

selector

made

at

should

be

the

engine

shift

lever

This

centers

the

control

interrupted

turn.

transmissions

the

transmission

neutral,

position.

in a forward

position.

the

boat

the

transmission

Forward

from

the

control

problem

lever

the

lever actuating

lever

actuating

Neutral

any

The

in a reverse

is

ill

may

before

position

time

below

made

at the

and

set the throttle

fluid

to

warm

to

the

actuating

in

tltis

and

the output shaft

are

equipped

engine

starter will not activate.

to

the

lever·

output shaft

direction.

to

the reverse position.

lever

output shaft and

always

toward

engine.

If

the

forward

be a result

by

the

gear shift

starting

to

1000

lowest

up

middle

position,

actuating lever

forward

on

direction

actuating lever

boat

position,

the

another

rpm and

practical

at

idle

for

a few

position.

lever

hydraulic

of

with

position.

the

transmission

and

the propeller

the transmission

the

(astern).

the

engine.

moves

backwards

of

incorrect

lever.

engine.

selector

in

engine

speed;

minutes.

You

on

the

power

the

transmis-

a neutral

is

peifectly

You

propeller

from

Neutral

Reverse

shut off

movement

posiany

should

trans-

safety

should

is

in

shaft

should

is

in

with

the

is

-.Y'

WESTERBEKE

Engines &

43

Generators

FORWARD

,

TRANSMISSION

DAILY

o o

OPERATION

Check

the transmission

Visually

check the gear shift

o Start the engine in

for

the

fluid

to

warm.

NOTE:

Too

Iowan

noise

from

the

transmission

such

cases

the

idle

o Shift into

gear.

BORG

WARNER

n

NEUTRAl

ACTUATING

neutral.

idle

speed

LEVER

fluid.

linkage

Allow a few

will

gear

should

VELVET

REVERSE

POSITIONS

and

transmission.

minutes

produce a chilltering

and

damper

be

increased.

at

plate.

idle

In

n

DRIVE

o

Clean used

fluid.

o

Refill

the

r

quantity and

the

,0

Check

o

Replace into

place and

o

Run

the

A

WARNING:

engine

is

hole.

This

Oil

Capacity

Approximately sions

to

the

have

a direct

will

be

required

angle

of installation

oil

required

TRANSMISSION

off the

transmission

will

vary

installation

the

dipstick

the

oil

filler

turn

engine,

Never

running.

could

cause

2.5

quarts

oil

level

relationship

to

fill

to

fill

the

depending

shutdown

Hot

fill

the

will

transmission.

and

properly

with

DEXTRON

on

the transmission

angle.

Pill

through

for

the

proper

fluid

cap

and

dipstick.

clockwise

pull

"uld

severe

mark

make a difference

and

out

will

(2.36

on

to

the

oil

cooler and

until

recheck

the

dipstick

splash

burns.

liters}

the

dipstick.

oil

capacity.

dispose

III

the level.

(press the

finger-tight.)

the

from

will

fill

Additional

the

cooler lines.

in

of

the

ATF.

The

model

dipstick

fluid

while the

most transmis-

Many

the quantity

hole.

dipstick

level.

the

dipstick

variables

oil

The

of

'

A

CAUTION:

cause

damage throttle on

back

the

transmission

Shifting

to

the

to

idle

engine

when

and

INSPECTION

o

Visually Check

worn.

o Lubricate

o Inspect the

check for

for wear

the

oil

leaks

on

the hydraulic lines and replace if

detent ball and shift cable attachments.

shift

linkage.

o Inspect the transmission

A

CAUTION:

sion

shift

positions.

CHANGING

After the initial 50 be

changed at

ter

haul-out.

becomes

o o

contaminated, Remove Remove

drain

into a container.

o Reconnect o

Use a suction through the

Clutch

failure

lever

does

not

THE

TRANSMISSION

hour

change,

every

300 operating

However,

the

oil oil

oil

pump

filler

filler cooler

the

changes

cap

cooler return

to

cap/dipstick

gears

above

1000

rpm

can

damper

shifting

the

damper

bolts;

fully

plate.

Pulling

gears

will

plate.

at

the

hydraulic connections.

retorque if

will

occur

engage

the

necessary.

if

the

detent

save

transmis-

ball

FLUID

the

transmission

hours

thereafter

fluid

must

be

changed whenever it

color,

or

smells

and

dipstick.

return

line and

line.

remove the transmission oil

hole.

allow

fluid

or

rancid.

the

wear

should

at

oil

to

win-

D1PSTICK'-----:i

MAKE

CERTAIN RUBBER SCREWED TIGHT HANDLE

Oil

Temperature

Amaxirnum mended.

ture

exceeds 2300P (110'e).

PRESSURE

An

optional

the

control transmission gear constant.

THE

SEAL

IS

TO'THE

oil

temperature

Discontinue

GAUGE

mechanical

panel

fluid. A normal

should indicate

operation

to

constantly

95

- 120 Ib-in'

of 1900P

pressure

monitor the

reading

FLUID

anytime

gauge

at 2000

(6.7 -8.4

LEVEL

(88°C)

sump

can

pressure

is

recom-

oil

tempera-

be installed

of

rpm

in

forward

kg-cm')

at

the

and

be

Engines & Generators

44

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission housing routine,

Periodically and

corrosion. checking (fluid

clean,

and

will

maintenance

check

change inspect

Make

the

fluid

appear

the

certain

level

as

strawberry

Lay-up/Winterize

Siorage

o

o o

o Loosen

o Inspect the

requires

Drain

the

replace it

NOTE:

This

raw

water

Clean

up

(use

heat

Fill

the

transmission

prevent

12

months

output

flange removing and

spray

Look

for

the

conduit,

all

moving

special

water

from

with

a proper mixture of antifreeze

operation

cooling

the transmission resistant

internal

attaching

the with

corrosion

system

paint).

corrosion.

or

more).

hardware

and

propeller shaft coupling

boat

from

lubricant.

gear

shift

of the end

and

bending of the actuator

parts.

is

minimal.

fluid

level

fluid

every

transmission

the

look

for

care.

Follow

the

transmission

will usually occur when

is

and

with Dextran III ATF

(Extended

the

cable,

'

Keep

as

part of

300

operating

and

the cooler

air

vent

is

clear

signs

of water

cream).

these

procedures:

oil cooler

properly winterized.

touch-up

from

water.

linkage,

fittings,

unpainted

storage

the

transmission

Separate the

and

cracks or

rods.

the

exterior

your

regular

hours.

for

leaks

and

when

contamination

and

coolant.

the

engine

areas

fluid

to

only,

flange

before

flanges

attachments.

cuts

Lubricate

in

WARRANTY

Service dealer.

BORG

placed ation

or Therefore made

at

ca,!sed

A

CAUTION:

occur resulting BORG related

If

any

problems occur

TRANSMISSION

NOTES

manuals

For assistance,

Velvet

1208 Liberty, Tel.:

www.VelvetDrive.com.

WARNER

on

its gears

fully

reversing

torque

low

engine

by

a shock

at

low

engine

in

damage

WARNER

torsional

is

are

available

Drive

Old

SC

(800)

is

aware

as

the

loads

speeds.

load,

System-related

not vibration

TROUBLESHOOTING

from

contact:

Transmissions

Norris

Road

29657

583-4327

of the

shock

result

of

mechanical

of

the

propeller

and

directional

If

it

is

any

warranty

noises speeds to

the

which

engine

responsible

of

this

with

the

transmission,

your

found

claim

can

and/or

for

type.

BORG

WARNER

loads

that can

propeller

blades

while

changes

should

,that

a failure

will

be

or

vibrations

cause

gear

transmission.

total

system-

see

in

this

manual.

be

oper-

shifting.

be

was

denied.

can

rattle

NOTE:

If

the

(twelve

months

fluid

to

prevent internal

before

putting

OIL

COOLERS

The continued time,

erode the

occur.

These

following

1.

2.

Either case

1.

2.

two

Transmission and

be

discharged

A loss

of

fail.

The

raw

water

ing

an

increase

fluid

will

will eventually

requires Install a Refill

new

the

transmission

or

the

flow

of raw water through the cooler

inside

internal

transmission

problems:

fluid

will

in

appear

fail.

an

oil

cooler.

cooler

as

is

to

be

more),

it

should

corrosion.

engine back

of the cooler causing

will leak into

overboard

fluid

leak into

transmission

strawberry

immediate

with DEXIRON III

leaks

will

into

will

the

through

cause

the

transmission

fluid.

cream.

response:

storedfor a

be

topped offwith

Reduce

service.

cause one of

the

cross

flow

of

the engine

the

transmission

This

contaminated

The

transmission

ATF.

long

fluid

leaks

raw

fluid

time

level

will,

in

to

the

water

exhaust.

caus-

to

If

water

has

contaminated

needs

to

be cleaned

take

several Check mission the

fluid

If

the

need

A

transmission

some waters,

WESTERBEKE

fluid

your

dipstick

fluid.

Change

lines that

transmission

the

attention of a

circumstances,

maintenance,

out

and

changes

each

the

connect

fails

to

qualified

cooler

may

depending

etc.

recommends

the

fluid,

the

replaced

to

get rid of

time

until it

transmission

to the

cooler.

shift

properly,

transmission

last

ten

years

on

operating

it

might

only

having a

transmission

with

fresh

the

contamination.

appears

filter

and

it

will

service

or

more

hours,

last

half

spare

fluid.

as

pure

clean

most

but,

that

cooler

fluid

It

will

trans-

out

likely

facility.

in

tropical time.

aboard.

/

Engines & Generators

45

LAY-UP & RECOMMISSIONING

GENERAL

Many

Owners

rely on

their

boatyards including engines off-season or

to

accomplish lay-up preparation themselves.

The procedures which

own

lay-up

check list if others These procedures should afford your engine protection

during a lay-up and

maintenance

If

you

have

your

local

provide

assistance.

Propeller

The transmission and propeller half couplings should be opened

out of

the

water or storage in the cradle. severe strain on the propeller shaft or coupling the boat

shaft apply not in period of

Fresh

A 50-50 solution of antifteeze and distilled water recommended for use in the coolant system at This solution antifreeze, depending solution

Should amount mixture. and cooling

is

has

actually been bent

to

small boats

use,

time.

Water

to

more

from

Operate

mixture

system.

Lubrication

With the engine warm, drain

sump. Remove with

new

oil.

ENGINE LUBRICATING OIL pages in this manual for the

oil changing procedure. Run the engine oil pressure and make sure there

A

CAUTION:

in

the

sump

combustion

chemicals

internal

and

generators, for lay-up during

for

long periods of inactivity. Others prefer

follow

and

recommissioning,

do

the procedures.

also

help familiarize

needs

of

your

engine.

any

questions regarding lay-up procedures, call

servicing

Shaft

up

taken out

unless

make sure

of the antifreeze concentration throughout the

dealer;

he will be more than willing

Coupling

and

the

bolts

removed when

moved

from land

The

flexibility of the boat often puts a

or

put in the

by

that

are hauled out of the water when

they

have been

Cooling

may

antifreeze the engine block and

the

Now

Circuit

require a higher concentration of

on

the area's winter climate. Check the

the

antifreeze protection

be

needed, drain

engine

to

recheck

System

and

replace the oil filter and

Use the correct grade

Do

not

leave

over

the

lay-up

deposits

which

parts.

combine

can

reduce

to

prepare their craft,

the

will allow

[Propulsion

these strains. This

ensure a complete circulation

the

all

period.

you

to

perform your

or

you

may

use

you

with

Engine]

the

boat

to

water,

and

or

both, while

water.

In some cases, the

dry

for a considerable

all

is

adequate.

an

appropriate

add a more

antifreeze solution's

the engine oil

of

are

no

the

engine's

to

produce

the

life

concentrated

from

fill

the sump

oil.

Refer

to

and

check for proper

leaks.

old

Lubricating

harmful

of

your

engine's

them

the

always

is

hauled

during

does

not

is times.

strength.

the oil

the

engine

oil

and

as

to

a

oil

Fuel

System

Top

off your

or

higher. stabilizer should be gasoline/water separator and

make

fuel.

Fuel

System

Top

off your

additives should be added prior

mix with the

Additives such should be added at this time condition the used

are separator used primary fuel filter/water separator and clean sediment bowl.

Change fuel system,

10

for 5 -

system. Check for the fuel system during this servicing, correcting them needed. Operating the engine for allow movement equipment on the engine.

Raw

Water

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

hose

from gallon bucket of clean fresh check the zinc anode found in the primary heat exchanger on the engine and clean any

zinc debris from inside the heat exchanger where the

zinc

anode

Start the engine and allow the

fresh water through the system. When

stop

the engine and refill the bucket with

solution slightly stronger than needed for winter freeze

protection

Start

the through the the

engine. This antifreeze mixture should protect the

water circuit from freezing during the winter lay-up,

as

providing

Remove the impeller from your

antifreeze mixture will accompany Examine the impeller. Acquire a replacement, if needed, a cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover

[Gasoline]

fuel

tanks with unleaded gasoline

A fuel conditioner such

added.

Change the element in your

and

clean the metal bowl. Re-install

certain there

are

no

leaks. Clean

as

Sta-Bil gasoline

of

up

any spilled

89 octane

[Diesel]

fuel

tanks with

fuel

being added and

as

Bio-bor and Diesel Kleen + Cetane Boost

fuel..

Care should be taken that the additives

compatible with the primary fuel filter/water

in

the system. Change the element in your

the

fuel

filter elements on the engine and bleed the

as

needed. Start

minutes

of

to

any

the

Cooling

the

seacock. Place the end of this hose into a

is

located.

in

your

area.

engine and allow

raw

water system. Once the bucket

corrosion

No.

2D

diesel

fuel.

Fuel

to

topping off

fuel

to

control bacteria growth and

the

engine and allow it

make sure

leaks that may have been created in

treated fuel through the injection

no

air

5· -10

to

ensure

still in the tank.

the

separator

is left in the fuel

minutes will help

Circuit

water.

Before starting the engine,

or

replace it

Clean

protection.

as

required, and also clean

the

raw

water

raw

water pump

all

of this mixture

raw

it,

the

water

so

strainer.

to

bucket is

an

antifreeze

to

pump

catch

it

and

draw

be drawn is

empty,

(some

in a bucket).

gasket.

they

to

run

as

five

the

empty,

raw

as

well

stop

and

-...v-

WESTERBEICE

Engines & Generators

46

Starter

Lubrication if batte!")' the

connections

Cylinder

If WESTERBEKE the and engine

injectors.

Be will

Intake

Clean cloth block through-hull to

CYLINDER

Spray arrester will plugs

NOTE:

and re-gapping at

Motor

and

access

to

the

connectiQns

starter.

Take

Lubrication

you

anticipate a

cylinder

squirt light

by

hand

sure

to

have a

have

any

Manifold

the

filter

lightly soaked

any

opening.

start-up!

fogging

removed,

stall

out

for

winter

The spark plugs

starter pennits

removed

head

needed

screen

exhaust

LUBRICATION

oil

the

Batteries

If

batteries are

make

sure that

to

prevent them

batteries will

subjected batteries environment.

to

and

to

they

not

severe

store

cleaning

care

are

shut

in

properly

from

of

[Diesel]

long

lay-up

recommends

(injectors

lubricating

1-2

revolutions

.

hardware

sealing

[Gasoline]

in

the

in

lube

Also

place

port,

into

the

while

the

engine

and

protection.

will

spring

be

left

on

are

fully

from

freezing.

remain

fully

environmental

them

in a warmer,

LAY-UP & RECOMMISSIONING

the

starter

drive

its

easy

removal.

off

before

attempting

replacing

the

starter.

period

(12

removing

if engine

oil

kit for

flame

oil

Make a note

open air

engine

coat

need

commissioning.

board

does

into

each

and

re-install

your

washers.

arrester,

around

the

an

oil-soaked

to

[Gasoline]

intake, is

running.

the

valves,

to

be removed

during

charged,

If

there

conditions,

and

is

more

pinion is

any

electrical

months

the

glow

not

have

cylinder.

the

engine

and

flame

cloth

remove

with

The

cylinders

the

lay-up

will

any

doubt

or

that

they

remove

compatible

Make

to

or

plugs

glow

Rotate

glow

to

ensure

place a

arrester

in

cloths

the

flame

fogging

for

cleaning

remain

will

advisable,

sure

the

remove

more)

from

plugs)

the

plugs

you

clean

to

the

prior

and

spark

period,

that

way,

that

the

be

the

Spare

Parts

Lay-up Westerbeke

or

coolant

and

kit during

SPARE

time

order

the

PARTS

Recommissioning

The

recommissioning

or

oil

seasonal those tion However,

counteracted

1.

2.

3.

4.

5.

6.

lay-up

described

regarding

Remove

discard removed Install

Reinstall lay-up, tenninals Check

Remove

proper

Check

circuit that

it solution engine

short

period

advisable, service,

heat

exchanger

area.

Start

the

in

the

manual.

provides a good

engine

to

see

if

external

hoses

need

replacement.

items

not

on

hand,

lay-up,

such

as

filters

section of

generally in

preparation

some

of

before starting

the

oil-soaked

the

raw

the

old

during

the

raw

the

batteries

and

reconnect

are

clean

to

make sure

the

spark

tightness [gasoline]. the

condition of

and

clean or

is

not

necessary

from

is

put into

of

as

to

inspect

engine

PREPARATIONS

this

of

your

follows

the

PREPARATIONS

for

the

lay-up

cloths

water

pump

gasket.

Install

lay-up

(or a replacement,

water

pump

that the

and

that

plugs,

the

replace

to

the

raw

water

operation,

time

with

either

an

end

the

area

and

clear

in

accordance

opportunity

or and

manual.

Westerbeke

starting

procedures

the

engine.

cover the

cover

were

battery

the

batteries

wipe

zinc

the

flush

coolant

the system will self-flush in a

no

adverse

of

where

any

FOR

to

inspect your

items

such

as

drive belts

Check your basic spares

replace those

zinc

the

same

FOR

and

from

the intake manifold.

and

raw

with a new

removed

cables,

connections

clean,

anode

the

antifreeze/fresh water

season

the

and all

with

procedures

STARTING

items

anodes.

will

water

are

re-gap,

system.

affects.

or

zinc

Refer to the

engine after a

procedures

STARTING sec-

normal

starts.

need

to

gasket

and

pump

if

required).

cover

during the

making

are

tight.

fully

charged.

and

in

the

raw

as

needed.

When

It

is

recommissioning

zinc

is

located

debris

described

section

used

as

be

impeller

gasket.

sure the

install

to

water

Note

the

in

the

from that

of

this

A

CAUTION:

eye

protection batteries can

be

ignited

cigar,

or

pipe.

the

battery equipment

ing

servicing.

Wear

rubber

when

servicing

emit

hydrogen, a highly

by

electrical

00

not

smoke

being

serviced.

in

the

vicinity

gloves, a rubber

batteries.

explosive

arCing

or

allow

Shut

off

all

to

prevent

electrical

Lead

gas,

a

lighted

an

open

electrical

apron,

and

acid

which

cigarette,

game

near

arcing

dur-

Engines & Generators

47

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 : Millimeters

Feet

(It) x .305 : Meters

Miles x 1.609 : Kilometers

METRIC

(mm)

x .0394:

(m) x 3.281 : Feet

(km) x .0621 = Miles

CONVERSION

Inches

DATA

DISTANCE

EQUIVALENTS

1

Degree

ofLatitude = 60

1

Minute

of

Latitude

VOLUME

Cubic

Inches

(in')

Imperial

Pints

(IMP Imperial Imperial Imperial Imperial Fluid US US US

Quarts Gallons Quarts Gallons

Ounces

Pints

(US

Quarts

Gallons

(IMP

x 29.573:

pt) x .473 = Liters(L)

(US

qt) x .946 : Liters

(US

gal)

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds

Per

Sq

In

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

Nm = 111.120

= 1

Nm : 1.852

x 16.387:

pt) x .568 = Liters

(IMP (IMP

x 3.785:

(psi) x 6.895 = Kilopascals

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

(Hg) x 3.377 = Kilopascals

(H,D) x .07355 = Inches

(H,D)

(H,D) x .248 = Kilopascals

Cubic

qt) x 1.137 : Liters

gal) x 4.546 = Liters

qt) x 1.201 = US

gal) x 1.201 = US

Milliliters x .034 = Ounces

Liters

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

x .03613:

km

Centimeters x .061

(L)

x 1.76:

(L)

(L) x .22 : IMP

Quarts

Gallons

x 2.113:

(L) x 1.057 = Quarts

(L)

x .264:

of

Mercury x 13.783 : H,D

psi

x 27.684:

(kPa)

:in'

IMP

pt

x.88 = IMP

(US

Pints

(kPa) x .145 = psi

(kPa) x .2961 = Hg

qt

gal

qt) x .833 = IMP

(US

gal)

x .833:

Gallons

H,D

x 4.026:

H,D

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles

Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

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

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water: 1 Gasoline Salt

Water

= 1

US

(in-Ib)

x .113:

(It-Ib) x 1.356 = Newton

x 1.609:

(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

gallon = 7.131bs

gallon:

gallon = 6.11bs

gallon:

8.56

Newton

Kilometers

(Kw) x 1.34 = MPH

8.33

Ibs

Meters

Per

MPG

(Nm) x 8.85

(Nm) x .738 = It-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

~

WESTERBEKE

Engines &

48

_Generators

SPECIFICATIONS

558

.AND

55lC

EN_G1NE.

Engine

Type

Displacement Combustion Combustion Bore & Stroke Max.

Max.

Aring Direction Propeller

Compression

Aspiration

Engine

Fuel

Dimensions -inches

Engine

Weight Air

Type

System

Angle

of

Installation

Angle

of

Rotation

Order

of

Rotation

Shaft

Ratio

Speed

Consumption

Only

Flow

TUNE-UP

Compression

Valve

Intake

Injection

Nozzle

Valve

(engine

Starting

Battery

DC

Starting

Starter Cold Alternator

liming

Opens

Closes

liming

Injector

Clearance

cold)

Battery

Capacity

Charging

Alternator

Aid

Cranking

Regulator

Pressure

Amps

SPECIFICATIONS

Diesel,

water

in-line

133

In-direct Swirl

3.35 x 3.78 Not Not

1-3-4-2

Counteltlockwise, Right 21:5:1 Naturally Idle

Cruising No

1.5 when

turn

in

forward

(mm)

Height: Width: Length:

4481bs Engine

Engine

cooled,

overhead

cubic

Inches

injection

chamber

inches

to

exceed

to

exceed

hand

direction

Aspirated

speed:

950-1000

Speed:

~ad

speed:

U.S.

gph

running

the

propeller

at

3000

RPM

23.3

18.6

27.0

(203.2

Combustion: Cooling:

valve

(2.179

14'

3~'

2000-2500

3200

kgs)

200

SPECIFICATIONS

441

psi

(3.04

MPa)

Open

at

15'

Open 16'

8' 1920

0.0157

ELECTRICAL

12 600 -800

50 Glow 12 175 -200

Internal

BTDC -Close

at

40'

BTDC -Close

BTDC-55-B

BTDC-55-C

psi

(13.2

inches

(0.4

SYSTEM

Volt,

(-)

negative

CCA

Amp

rated,

belt-driven

plugs,

12V

Voh,

1.8

KW

Amps

regulator,

MPa)

(min.)

sheathed

with

four

type

(85 x 96

for

30

when

of

rotation

RPM

at

2500

used

at

full

inches inches inches

116 cfm

mm)

ground

solenoid

built

into

cycle,

four

liter)

mm)

minutes

viewed

from

RPM

(neutral)

RPM

allows

the

open

throttle

(592

(472

(687

cfm

(3.3

(5.6cmm)

29'

ABDC

16'

ATDC

-12V

alternator

cylinder,

flywheel

(approx.) engine

underway

mm)

mm) mm)

cmn)

to

General Fuel

Injection

Fuel Injectors Fuel

Air

cleaner

Fuel

General

Operating Fresh Raw

System Sea

at

3000

General Oil Sump

(not Operating

(engine Oil Oil

General clutch

Gear

Propeller

Lubricating

Transmission

Capactty

Pump

Filter

Lift

Pump

Temperature

Water

Pump

Water

Pump

Capacity

Water

Flow

rpm

Filter

Capacity

Including

Oil

Pressure

hot)

Grade

Cooler

Ratio

(standard) 1 :88:1

Recommendations

Fluid

FUEL

Self

bleeding Diesel BOSCH, Throttle

Primary, Replaceable Solid

COOLING

Fresh heat

exchanger. 170-190' F Centrifugal

Positive belt-driven.

7.25

US

8.0 -8.5 (measured injected

LUBRICATION

Forced Full

flow

8

filter)

U.S.

43 -85

API

Specification

Fresh

TRANSMISSION

ZF

Marine

gears,

18 x 13P-2blade

(Propeller reach full

open

gear) Automatic

or

III

Sump

0.75

SYSTEM

fuel

#2

(catane

rating

PFR

type

full

flow,

spin-on

element

paper

cartridge.

state

wtth

external

filter

SYSTEM

water-cooled

displacement,

exhaust

with

(77

-

88'

metal

impeller

qts

(6.86

liters)

gpm

(30.2 -32.1Ipm)

before

discharging

elbow)

tube

C)

type

rubber

SYSTEM

lubrication

qts

water

with a servo-operated

(ZF25M)

its

U.S.

by

Trochoid

spin-on

(7.6

liters)

psi

(290 -590

CF

or

cooled

Transmission,

(RH)

used

should

full

rated

RPM

throttle

while

transmission

qts.

(0.79

liters)

KPa)

CG-4,

case

or

18

allow

(3000 + 000

underway

fluid,

of

45

or

and

shell

belt-driven.

impeller,

into

water

type

pump

SAE

30,

hardened,

multiple

x

11

P 3

the

engine

in

type

Dexron

higher)_

type

15W-30

helical

disc

blade

(RH)

to

-100)

at

forward

II

EXHAUST

Exhaust

Elbow

Exhaust

Hose

Size

Exhaust

Gas

Flow

Muffler

Size

min.)

45'

3.0" 265 14" x t4"

SYSTEM

elbow

1.0.

hose

cfm

at

3000

RPM

~

WESTERBEKE

Engines

49

& Generators

SPECIFICATIONS

550

ENGINE

Engine

Type

Displacement

Combustion Combustion Bore & Stroke Max. Max.

Firing

Direction

Propeller

Compression

Aspiration Engine

Fuel

Dimensions ~ inches

Engine

Weight Air

Type System

Angle

of

Installation

Angle

of

Rotation

Order

of

Rotation

Shaft

Ratio

Speed

Consumption

Only

Flow

TUNE-UP

Compression

Valve Intake

Intake

Injection Nozzle Valve

(engine

Starting Battel)!

DC

Starting

Starter

Cold

Alternator

liming

Opens Closes

Timing

Injector

Clearance

cold)

Battel)!

Capacity

Charging

Aid

Cranking

Regulator

Pressure

Alternator

Amps

SPECIFICATIONS

Diesel,

water

overhead

cubic

inches

injection

chamber

inches

exceed

to

exceed

hand

direction

Aspirated

speed:

950-1000

Speed:

load

speed:

U.S.

gph

the

propeller

at

2600

Ibs

(203.2

Combustion: Cooling:

cooled,

valve

(2.179

(85 x 96

W

30°

for

when

1800-2200

2750

running

used

RPM

at

23.9

inches

21.0

inches

35.4

inches

kgs)

100

in-line 133

In-direct Swirl

3.35 x 3.78 Notto

Not

1-3-4-2

Counterclockwise, Right

21

:5:1 Naturally Idle

Cruising No

1.6 when

turn

in

forward

(mm)

Height: Width:

.

Length: 448 Engine

Engine

SPECIFICATIONS

441

psi

(3.04

MPa)

Open

at

150 BTDC -Close

Open

at

400 BTDC -Close 80 BTDC 1920

psi

(13.2

MPa)

0.0157

inches

(0.4

mm)

ELECTRICAL

12

Volt, H negative

400 -600

50

Amp

Glow

12

Volt,

175 -200

Internal

CCA

rated,

plugs,

12V

1.8

IIiN

Amps

regulator,

SYSTEM

(min.)

belt-driven

sheathed

with

built

four

cycle,

type

liter)

mm)

30

minutes

viewed

of

rotation

RPM

(+

at

2200

allows

full

open

100

elm

cfm

(2.8

290 ABDC 160 ATDC

ground

-12V

solenoid

into

four

cylinder,

-

from

flywheel

or-)

RPM

(approx)

the

engine

throttle

underway

(592

mrn)

(472

mm)

(687

mm)

(2.8

cmn)

cmm)

alternator

to

General

Fuel Fuel

Injection

Pump

Injectors

Fuel

Filter

Air

cleaner

Fuel

Lift

Pump

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

System

Capacity

Sea

Water

at

General

Oil Sump

(not Operating

(engine Oil Oil

General

clutch Gear

Flow

2600

rpm

Filter

Capacity

including

Oil

hot) Grade Cooler

Ratio

(standard)

Propeller

Recommendations

Lubricating

Transmission

Capacity

Fluid

FUEL

Self

bleeding Diesel BOSCH,

Throttle

Primary,

Replaceable Solid

COOLING

Fresh

heat

exchanger.

170

-1900 F

Centrifugal

Positive belt-driven.

7.25

7.0 -7.3

(measured

injected

LUBRICATION

Forced Full

flow

8.9

filter)

Pressure

U.S.

43 -85

API

Specification

Fresh

TRANSMISSION

ZF

Marine

gears,

1:88:1 18 x 12P-2blade

(Propeller reach full

open

gear) Automatic

or

III

Sump

0.75

SYSTEM

fuel

#2

(cetane

rating

PFR

type

full

flow,

spin-on

element

paper

cartridge.

state

with

external

filter

SYSTEM

water-cooled

displacement,

US

qts

exhaust

with

(77 -88'

metal

impeller

(6.86

liters)

gpm

(26.5 -27.6Ipm)

before

discharging

elbow)

lube

C)

type

rubber

SYSTEM

lubrication

water

with a servo-operated

(ZF25M)

its

U.S.

by

Trochoid

spin-on

qts

(8.4

liters)

psi

(290 -590

CF

or

cooled

Transmission,

(RH)

used

should

full

rated

RPM

throttle

while

transmission

qts.

(0.79

liters)

KPa)

CG-4,

case

or

18 x 10P 3 blade

allow

(2600 + 000

underway

fluid,

of

45

or

and

shell

belt-driven.

impeller,

into

water

type

SAE

30

hardened,

multiple

the

engine

in

type

higher).

type

pump

15W-40

helical

disc

to

-100)

forward

Dexron

(RH)

at

II

EXHAUST

Exhaust

Elbow

Exhaust

Hose

Size

Exhaust

Gas

Flow

Muffler

Size

(min.)

450 elbow 9 (#044876)

3.0" 230 14" x 14"

SYSTEM

I.D.

hose

cim

at

2600

RPM

Engines & Generators

49A

.

CONTACT

YOUR

WESTERBEKE

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

DIESEL

SUGGESTIONS

PARTS

ENGINES

AND

ADDITIONAL

INFORMATION

HARDWARE

KIT

·ZINCANODE

RAW

WATER

PUMP

IMPELLER

AND

O-RING

BELTS

WESTERBEKE HAVING FOR

FUEL/WATER FILTER

.

CARTRIDGES

WESTERBEKE each packaged in a rugged hinged Kit "A" includes

Kit

"B"

is

KITA

ZINC DRIVE OIL FUel HEAT IMPELLER FUEL FUEL

also

offers

the

basic spares.

for

more

extensive

.

ANODES

BELTS

FILTER

FILTER EXCHANGER

KIT SYSTEM PUMP

INLET

two

off-shore

GASKET

HARDWARE

FILTER

ENOUGH

AT

LEAST

Spare

toolbox.

I(IT

ALSO

ONE

Parts

Kits,

cruising.

RECOMMENDS

OIL

ON-BOARD

OIL

CHANGE

SPARE

PARTS

Engines & Generators

KITS

KIT

B

ZINC

ANODES

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER IMPELLER INJECTOR OVERHAUL

AIR

GLOW

FUEL FUel

KIT

FILTER

PLUG

SYSTEM PUMP

.

GASKET

INLET

KIT

HARDWARE

FILTER

MOLDED HOSE

KIT

INA

CANVAS

CARRYING

BAG

KIT

50

-.¥'

WESTERBEKE

Engines & Generators

..

··8/14;2011,/1162

.

Westerbeke 55B-FOUR, 55C-FOUR, 55D- FOUR Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual