Westerbeke 64A FOUR Operator's Manual

OPERATORS

MANUAL

MARINE

DIESEL

64

ENGINES

F

member

-

~

PUBLICATION

FIRST

DECEMBER

WESTERBEKE

150

JOHN

TEL:

CORPORATION·

HANCOCK

[phone].

ROAD,

FAX:

NO.49112

EDITION

2003

MYLES

TAUNTON,

[phone]·

STANDISH

MA

INDUSTRIAL

02780-7319

WEBSITE:

www.WESTERBEKE.COM

U.S.A.

PARK

A

WARNING

Exhaust
colorless
unconsciousness
exposure

-Dizziness

-Nausea

-Headache

-

IF
GET
seek
until

gasses

gas.
can

Weakness

YOU

OR

ANYONE

OUT

INTO
medical
it

has

been

contain

carbon

and

include:

and

Sleepiness

THE

attention.

inspected

carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

A

WESTERBEKE

bulkhead

WESTERBEKE

CARBON

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY.
down

repaired.

WARNING

an

of

Carbon

in

Twitching

to

Think

ANY

OF

If

the

unit

and

DECAL

and

near

your

also

MONOXIDE

odorless

and

Temples

THESE

symptoms

is

should

engine

recommends

DETECTORS

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

do

not

restart

provided

by

be

fixed

or

generator.

to

a

installing
in

the

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

of

State

WARNING

gasoline

its

birth

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this
caused
tions.
necessary
and your
The
American

PREVENT

A

while

power.

•

• Shut off electrical

•

•

•

•

• Electrical

PREVENT

A

exhaust

very

•

A

•

safety

by

failure

Know

when

precautions

machinery.

following

safety

Boat

ELECTRIC

WARNING:

engine

is

Lethal

Do

not

operate

enclosures

equipment.
Use

equipment.
Make

(particularly
Remove

electrical
Do

circuits,
transfer

result if

tor.

and

insulated

sure

your

wristwatch

equipment.

not

connect utility

except
switch.
this

shock

Discharge

BURNS -HOT

WARNING:

system

hot!

Always
recovery

check

tank.

WARNING:

In

case

of

an

before

touching

manual

to

follow

dangerous

instructions

and

Yacht

Do

running,

voltage

this
covers

power

mats

clothing

shoes)

through a ship-to-shore

Damage

procedure

results

capacitor

Do

components. A running

the

engine coolant

Steam

engine

the

carefully.

Most

fundomental

conditions

to

protect

yourself,

are

in

Council

(ABYC)

SHOCK

not

touch

AC

electrical

or

when

connected

is

present

machinery

in

whenever

when

and

shore

is

from

at

these

without

place.
before

accessing

working

and

skin

are

handling

all

jewelry

power

to

vessel's

not

followed.

handling a charged

by

shorting

ENGINE

not

touch

hot

engine

level

can

cause

injury

overheat,

engine or checking

allow

accidents
rules

and

exist and

your

personne~

compliance

standards.

connections

to

connections!

electrical

electrical

on

electrical

dry,

not

electrical

when

working

to

vessel's

double

AC

generator

terminals

parts

engine

at

the

or

death!

the

engine

the

coolant.

are

precau-

take

the

with

the

shore

damp

equipment.

on

AC

throw

may

capaci-

together.

or

gets

coolant

to

cool

PREVENT

A

•

Prevent
sparks
pump,
vapors.
removing

•

Do
arrester
death.

•

Do
Backfire

•

Do
the
engine/generator clean

chances

•

Be

PREVENT

A

injury

•

Follow
hatches
after
ning
starting

•

All
when
tilated area
out of

•

Do

•

Shut
the
spill.
sources
ing.
fuel

•

Do

•

Be

•

Be
free

•

Make
properly
Extinguishers
for

BURNS -FIRE

WARNING:

flash

fires.

to

occur near

or other potential

Use

a suitable container

the

not

operate

removed.

not

operate

can

cause

not

smoke

fuel

system.

of fire.

aware -diesel

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling

closed
fueling.
the

fuel

not

off

fuel

DO

Ensure

system.

not
sure
certain

of

all

Check

blower.

your

engine.

vapors

handling

away

the

reach

fill

the

the

fuel

system.

NOT

of

fire

proper ventilation

alter

or

all

fuel

fuel

leaks.

sure a fire

maintained.

applications encountered

Fire

can

Do

not

the

carburetor,

fuellme,

or permit

with

Backfire

with

severe

Keep

Wipe

fuel

carburetor,

a Coast

the

air cleaner/silencer

the

and

up

will

Explosions

safety

when

fueling.

below

Run

the

are

highly

and

storing

from

spark-producing

of children.

fuel

tank(s)

service

valve

Take

care

allow

any

near

the

fuel

modify

line

rated

the

supplies

fittings

extinguisher

Be

ABC

cause-;njury

smoke

sources

Guard

can

injury

flames

compartment

free

all

spilled

burn.

from

instructions.

Open

for

blower

explosive.

fuels.

while

at

in

catching

smoking,

system

fuel

have a positive

are

is

familiar

by

the

or

or permit

fuel

of spilled

to

catch

or

fuel

Approved

cause

severe

or

death.

or

sparks

of

debris

fuel

fuel

vapors

Keep

and

fumes/vapor

for

four

Use

Store

the

engine

the

engine

any

open

or

engine

exists

when

system.

adequately

installed

with

NFPA

in

this

death!

flames

line,

filter,

fuel

or

all

fuel

when

filters.

flame

injury

removed.

to

occur

and

the

to

minimize

and

engine

can

cause

the

vessel's

ventilate

extreme

fuel

equipment

shutoff

its

are

environment.

cabin

before

minutes

care

in a well-ven-

is

running.

when

servicing

fuel

that

flames,

or

when

servic-

servicing

valve.

tightened

nearby

and

proper

use.

appropriate

or
fuel

fuel

or

near

the

oil.

run-

before

and

might

other

the

and

is

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect
generator.
it

last.

•

Make
starting.

•

Make
installed before starting

BATTERY

A

WARNING:

or

death!

•

Do

not
being
highly

arcing
equipment
ing

servicing.

•

Never
tive
not test
together.
Ventilate
accumulation of
disturb
is

being

•

Avoid
bums
wristwatch,
the

battery.

•

Always
the

battery connections.

and

BATTERY

STARTING

Accidental

the

battery cables before

Remove

certain

all

personnel

certain

all

covers,

EXPLOSION

Battery

smoke

or

allow

serviced.

explosive
or

connect

(+) connection terminal of

the

contacting

or

reconnect it last

Lead

gas,

by

lit

tobacco

in

the

vicinity

the

the

battery condition
Sparks could ignite battery
any

compartment containing batteries

explosive

battery charger connections

charged.

sparks

that could cause

rings,

tum

the

battery charger off before disconnecting

ACID

the

negative

explosion

an

acid

which

negative

the

terminals

and any

when

starling

are

guards,

the

engine.

open

batteries emit

products.

to

prevent

(-) battery cable

gases.

other jewelry before handling

Remove

disconnecting

can

cause

servicing

lead

first

and

clear of

can

by

the

and

hatches

can

cause

flame

near

hydrogen,

be

ignited

Shut off all electrical

electrical

the

starter

solenoid.

shorting

with

an

gases

To

avoid

while

tools,

explosion.

the

negative

the

the

injury

the

reconnect

engine before

are

re-

injury

the

battery

by

electrical

arcing

to

the

terminals

or

fuel

to

sparks,

the

etc.,

to

Remove

lead

battery.

engine!

a

dur-

posi-

Do

vapors.

prevent
do

not

battery

prevent

first

TOXIC

• Ensure that

•

•

• For additional information refer

•

•

•

AVOID

EXHAUST

A

WARNING:

discharged
regularly
are

securely
attention
exhaust pipe

Be

sure

the

In

addition
install a carbon monoxide
builder or dealer for installation of

tional information

A

WARNING:

odorless

nausea

gas.

or

death!

Do

not

use

fumes

can

tems.

Exhaust sulfur causes rapid deterioration of copper

tubing resulting
Do

not

install exhaust outlet
through
exhaust discharge outlet
enter
flow

Although
exhaust
gas
toms
are:

Vomiting
Dizziness
Throbbing

the

of

is

present

or

exhaust.

portholes,

fumes

signs

MOVING

GASES

Carbon

monoxide

the

exhaust system

from

the

engine.

for

leaks

and

make

attached

to

the

nipple.

unit

to

Inhalation

copper tubing

rapidly

exhaust

diesel

in

and

no

manifold, water injection

and

its surroundings

routine inspection of

detector.

on

Carbon

Carbon

monoxide

produces

in

destroy

in

discharge

Avoid
engine exhaust

from

in

diesel

of carbon monoxide inhalation or

temples

copper

exhaust/water

vents,

or air conditioners.

is

near
outlet

overloading

gasoline

exhaust

Muscular twitching
Intense.
Weakness

PARTS

Check

sure

warping

Monoxide).

diesel

where

engines,

(CO)

is a deadly

is

adequate
the

the

approved

to

ABYC

(CO)

flu-like

exhaust

tubing

leakage.

the

and

gases

fumes.

headache

and

to

the

exhaust

exhaust

exists.

elbow,

are

well

exhaust

Consult your boat

T-22

is

an
symptoms,

systems.

in

exhaust

exhaust

waterline,

close

or

the

craft.

are

not

carbon

Some

sleepiness

gas!

expel

gases

system

manifolds

Pay

close

and

ventilated.

system,

detectors.

(educa-

invisible

Diesel

sys-

can

be

drawn

If

the

engine

water

restrict

as

toxic

monoxide

of

the

symp-

poisoning

could

the

as

A

WARNING:

severe

injury

•

When

servicing

level,

wear

tion.

Batteries contain sulfuric

If it

comes

with

water.

inadvertently

Sulfuric

or

death!

rubber
in

contact

Acid

when

acid

in

batteries

the

battery or checking

gloves,

may

a rubber

acid

with

your

skin,

splash

on

the

removing electrolyte

apron,

which

wash

skin

can

the

electrolyte
and
is

destructive.

it off at

or

into

caps.

cause

eye

protec-

once

the

eyes

Engines & Generators

ii

A

WARNING:

or

death!

•

Do

not

service

tion

arises

in
operating adjustments,
moving

parts

Rotating

the

which

and

parts

engine

while

it

is

absolutely necessary

use

hot exhaust system

can

it

extreme

cause

injury

is

running.

care

to

components.

If

to

avoid

a

situa-

make

touching

SAFETY

•

Do

not

wear loose clothing or jewelry when servicing

equipment; tie back long hair and avoid wearing loose

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

could be caught in moving parts.

• Make sure
Keep
places at

•

Do
the engine

• Stay clear of the drive shaft and the transmission coupling
when the engine
be

caught

HAZARDOUS

A

WARNING:

all

attaching hardware

protective shields and guards

all

times.

not check

fluid

levels or the drive belt's tension while

is

operating.

is

running; hair and clothing can easily

in

these rotating parts.

NOISE

High

noise

levels

is

properly tightened.

in

their respective

can

cause

hearing

INSTRUCTIONS

loss!

• Never operate

•

Do

not

removed.

•

Do

not

open.

A

WARNING:

mentally

an

engine without its muffler installed.

run

an

engine with the air intake (silencer)

run

engines for long periods with their enclosures

Do

not

wotlc

on

or

physically

machinery

incapacitated

by

fatigue!

when

you

are

ABYC,
INSTALLING

Read the following ABYC,

for safety codes and standards. Follow their recommenda­tions when installing your engine.

ABYC (American Boat and

"Safety Standards for Small Craft"

Order

NFPA

"Fire Protection Standard for Motor Craft"
Order

USCG

"USCG 33CFR183"
Order

NFPA

AND

USCG

PUBLICATIONS

DIESEL

from:

ABYC

15

East 26th Street

New

York,

NY 10010

(National Fire Protection Association)

from:

National Fire Protection Association

11

Tracy Drive

Avon

Industrial Park

Avon,

MA 02322

(United States Coast Guard)

from:

U.S.

Government Printing

Washington,

D.C.

ENGINES

NFPA

Yacht

Office

20404

and USCG publications

Council)

FOR

OPERATORS

Many

of the preceding safety tips and warnings are repeated

in

your Operators Manual along with other cautions and

notes

to
carefully, maintain your equipment, and follow
procedures.

ENGINE

Preparations
ough examination
(ABYC) standards. These standards are a combination of
sources including the USCG and the

Sections of the ABYC standards

H-2 Ventilation

P-l Exhaust systems

P-4 Inboard engines

E-9
All

installations must comply with the Federal Code of

Regulations (FCR).

MANUAL

highlight critical information. Read your manual

all

safety

INSTALLATIONS

to

install

an

engine should begin with a thor-

of

the American Boat and

DC

Electrical systems

NFPA.

of

particular interest

Yacht

Council's

are:

Engines & Generators

iii

When

installing

attention be paid

WESTERBEKE

to

the

following

INSTALLATION

engines
information:

and

generators

it

is

important that strict

CODES

Strict
when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For installations

or

will

be

break

in

the

minimum

the exhaust

water

line

flooding

If

you

have

to

the

vessel's waterline under

siphon-break.

NOTE:

A

siphon-break
operation.
engine

damage.

EXHAUST

The

exhaust

prevent water

where

below

the

vessel's

raw

water

of

20"

above

manifoUJ/water

of

the

vessel

of

the

vessel.

any

doubt

Failure

to

Consult

SYSTEM

hose

must

from

entering

properly

ABYC

and

generators

the

exhaust

waterline,

supply

hose

the

vessel's

injected exhaust

will

result in

about

the

the

requires

periodic

maintain a siphon-break

the

siphon-break

be

certified

the

guidelines,

manifold/water injected exhaust
to

waterline.

position of

vessel's

and

in a marine

provisions

the

exhaust

raw

water

the

various

inspection

safety

codes

environment.

must

be

made

elbow.

This

Failure

elbow

to

use

is

near or

damage

water-injected exhaust elbow relative

to

operating

and

cleaning

can

manufacturer

for

marine

exhaust under

use.

any

The

system

sea

conditions

for

must

be

complied

elbow

to

install a

hose

must be looped a

a siphon-break

below

the

loaded

the engine and

conditions,

result

proper

must

install a

to

ensure

in

catastrophic

maintenance.

be designed

and

at

any

is

close

siphon-

when

possible

proper

angle

with

to

to

AVAILABLE
YOUR

WESTERBEKE

DEALER

FROM

A

detailed
diesel,
dealer.

40

page

engines

Marine

and

generators,

Installation

is

available

Engines & Generators

Manual

from

iv

covering

gasoline

your

WESTERBEKE

and

TABLE

Parts

Identification

Introduction

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

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

Admiral
Captain
Fuel,

Engine

Preparations

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

Control
Control

Oil

for
Starting/Stopping
Warning
Engine
The

Maintenance
Fuel

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

Fuel

Cooling

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

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

Raw
Raw
Raw

Raw

Heat
Zinc

Engine

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

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

Remote
Water
Tachometer
DC

Alternator

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

Lights,

Break-In

Daily

Operation

Schedule

System

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

Filters ......................................................

System

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

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

Water Intake Strainer .............................. 18

Water

Exchanger .............................................. 19

Anode ..................................................... 19

Pump

Lubricating

Oil

Filter

Heater

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

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

Electrical

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

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

Panel
Panel

Alarms

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

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

and

Coolant

Initial

Procedure

Procedure

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

Start-Up

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

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

and

Circuit

Breaker

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

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

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

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

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

0i1

....................................... 20

(Optional)

System

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

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

....

OF

l0

11

12
13

15
15
15

16

17

18

18

21
22
23

24
24

CONTENTS

2
3

5

6

7

8

9

Glow

Plugs

W""

Wiring
Starter

Dual
Engine

Engine

Hurth

Borg

La

Metric
Engine

0"

iring

lagram ..................................................

Schematic

Motor

Output

Troubleshooting ............................................. .32

Troubleshobting

Adjustments

Belt Adjustment .............................................. 35

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

11

. E . C .

estmg ngme ompresslOn .......................... 36

Valve Clearance Adjustment .......................... 36

Idling Speed .................................................... 37

Stop Solenoid .................................................. 37

Oil Pressure .................................................... 38

HSW

Specification ...................................................

Fluid Change ............................................ .40,41

Shipment ......................................................... 41

Transmission Fluid ........................................ .41

Changing Filter .............................................. .42

Cable Connections ........... ; ............................. .43

Couplings .... : ................................................... 43

Transmission Coolers ................................... .43

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

Warner

Maintenance ..................................................... 48

Oil Coolers ............................................... ~ .......

y-up

an
Conversions
Specifications

Suggested

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

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

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

Alternators

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

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

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

Transmissions

Transmission

d R

ecommlsslonmg

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

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

"""

Oata

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

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

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

~pare

Parts

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

26

27

.28

29

.

31

33

.35

39

40

44

.47

49

5,0

51
52
53

Engines & Generators

1

DC

FUEL

RAW

CHARGING

LIFT

PUMP

WATER

PARTS

IDENTIFICATION

WATER

INJECTED

_EXlrlAU!~T

ELBOW

REAR

TRANSMISSION

FRONT

AIR

INTAKE/AIR

SILENCER

PREHEAT

HEAT

IiULltNUIU,

ZINC
ANODE

EXr::HA~IGEFI---

REAR

FILTER

.

20

AMP

CIRCUIT

LEFT

SIDE

.jk.~~~~"",

FILL

=......--MANIFOLD

ENGINE
DRAIN

PLUG

I.D.

PLATE

ALTERNATOR

FRONT

BLOCK

HBW

HURTH
TRANSMISSION-Q."-'''''''''"III!

TRANSMISSION
SHIFT

LEVER

AND

FLEXIBLE
MOUNT

Engines & Generators

2

MOTOR

SOLENOID

BELL

ASSEMBLY

RIGHT

OIL

HOUSING/FLYWHEEL

SIDE

DRAIN

HOSE'

INTRODUCTION

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

you

In

order

to
important
manual
manual carefully
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer

This
provided
WESTERBEKE
equipment, contact your WESTERBEKE dealer
WESTERBEKE'S installation

that

is

designed

is

your operators

and

WARRANTY

Your

WESTERBEKE

folder.

If, after

you

form
registering your
writing with

serial number

have not received a customer identification card

Customer

Customer Identification
MR.

ENGINE OWNER

MAIN

STREET

HOMETOWN,
Model

64A

Expires 3/20/04

long

years of experience

We

take

great pride

for

selecting

get the

you operate

a technical manual

WESTERBEKE.

full

use

to

help

and

observe

manual.

dealer.

If

and

and

you

you

PROCEDURES

Warranty

60

days

of submitting

warranty,

model

and

commission

please contact

information, including the engine's

Identification

USA

FOUR

is

a product of

and

in

the

superior durability

benefit

from

your

maintain it

do

this.

all

the safety precautions

A parts catalog

is

are

planning

manual.

is

date.

correctly.

Please read

for

assistance.

available

included in a separate

the

Warranty
the

from

to

factory

Card

Serial Number

advanced

engine,

This

this

is

also

your

install

for

Registry

in

this

and

it

is

PRODUCT

Product software, (technical data, parts lists,
brochures
WESTERBEKE

WESTERBEKE
CONTENT OF SUCH
WARRANTIES
THERETO,
COMPLETENESS THEREOF AND
BE LIABLE
INCURRED

OF

THE

WESTERBEKE customers should
span
and

the
product software. The product software provided
WESTERBEKE products, whether
other suppliers, must
exclusively

product.
appropriate representatives ofWESTERBEKE
plier in question
currentness of
customer.

NOTES,

As

this
maintenance schedules, and troubleshooting of your
engine, critical information will
CAUTIONS,

NOTE:

A

observed.
your

SOFTWARE

manuals,

and

catalogs), provided

are

not within WESTERBEKE's

CANNOT BE RESPONSIBLE

SOFTWARE,

OR

REPRESENTATIONS

INCLUDING

FOR

ANY

IN CONNECTION

FURNISHING

between printings of WESTERBEKE product software

unavoidable existence of earlier

as

the definitive authority

It

not

only

be

the

product software being consulted

CAUTIONS

manual

An operating procedure essential

CAUTION:

takes

and

WARNINGS.

Procedures

can

result

ACCURACY,

TYPE

OR

not

and
makes
consulted

AND

you

through the operating procedures,

in

the

engine.

from

sources other

MAKES

TIMEUNESS

WILL

OF DAMAGE

WITH

OR

USE

OF

SUCH

keep

in mind

WESTERBEKE

from

WESTERBEKE

cannot be relied

on

the

good sense but

to

determine

WARNINGS

be

highlighted

An

explanation

to

which.

if

not

damage

or

destruction

FOR

NO

WITH

RESPECT

IN

NO

OR

INJURY

ARISING OUT

SOFTWARE.

the

with

upon

respective

is

imperative that

or

the

the

accuracy

by

follows:

note.

strictly

than

control.

THE

OR

EVENT

time

sup-

and

by

the

marine

NOTES,

of

or

A

WARNING:

followed.

Engines & Generators

3

can

result

Procedures

in

which.

personal

if

injury

not

properly

or

loss

of

life.

INTRODUCTION

SERIAL

The
the

The engine's serial number

on a flat
time

plate shown

when

Fill

UNDERSTANDING

The
the
arranged
general
same
lubricating

Therefore,
preventive
tant
the
filter
and
in
the
lubrication

The
however,
carburetor
component ­function

NUMBER

engine's model number and serial number

nameplate mounted

swface directly above the injection

to

enter this information

below,

seeking technical information and/or ordering

in

the

infol71lationforyour

diesel

engine closely resembles

mechanism

above

type

as

type

of

system.

to

maintenance

factors

are

fuel,

lubricating and cooling systems. Fuel

elements must

frequent checking

the

fuel

system

consistent

oil

diesel

engine

in

its

and

of

both.

LOCATION

on

the side of the engine's manifold.

is

stamped into the engine block

on

the illustration of the

as

this will provide a quick reference

reference.

THE

DIESEL

is

essentially

a closed crankcase. The crankshaft

a gasoline engine, and

valves,

camshaft, pistons, connecting rods and

a great extent, a diesel engine requires

as

a gasoline

proper ventilation

be

replaced at

for

contaminants

is

also

essential. Another important

use

of

the

same brand of high detergent

designed specifically

does

differ
method of handling
ignition systems

the

fuel

injection

the

from

pump

same.

are

ENGINE

the

engine.

and

the

for

the

and

replaced

- which performs

are

located

pump.

~

gasoline engine, since

The

cylinders

is

the

diesel engine

The most

proper maintenance of

and

lubricating

time

periods

(water,

sediment,

diesel

engines.

gasoline

firing

engine,

of

by

a single

fuel.

on

Take

the

name-

parts.

are

the

same

has

the

same

impor-

specified,

etc.)

factor

diesel

The

the

the

is

ORDERING

Whenever replacement
engine
the

silver
must provide
identify
description
separately furnished
packaged parts because
not

made

SPARES

Certain spares
WES1ERBEKE
will

assist

the

SPARE PARTS

sories,

PARTS

model

number

and

black nameplate located

us

with

this

your

engine.

and

to

the same specifications

AND

you

see

WES1ERBEKE'S ACCESSORIES

In

part

number
Parts

ACCESSORIES

will

be

engine.

in

preparing

page

parts

are

needed,

and

serial

number

infor:mation

addition, include a complete part

for

each part

List). Insist

will fit

or

needed

to

support

Your

local WES1ERBEKE dealer

an

inventory of

in

this

manual.

always
as

they

on

the

manifold.

so

we

may

needed

upon

WES1ERBEKE

generic

parts

as

original equipment.

and

maintain

spare

For engine

provide
appear

properly

(see

are

frequently

parts.

acces-

brochure.

the

on

You

the

your

See

GLOW

ENERGIZED

BY

THE

PRE·COMBUSTION

PLUG·

PREHEAT

BIlTTON:.e5115'

17"1:a------¥A---IJI~SEL

CHAMBER-2~~~~~

FUEL

SPRAY

Engines & Generators

4

DESCRIPTION

This

manually-operated control panel

KEY

switch

and

RPM

gauge

meter

which

measures the engine's running time

in

1/10

hours.

The

panel
ATURE
Fahrenheit,

engine's

. control circuit

tem's
switch
is
pushbuttons, one

RPM
TERS
PER
ENGINE
RECALiBRATED
ACCURACY
REAR

gauge which indicates water temperature

an

OIL

PRESSURE gauge which measures

oil

pressure

in

pounds per square inch,

VOLTAGE

voltage.

in

operation. The panel also contains

GAUGE:

REVOLUTIONS

MINUTE

AND

OF

THE

is

turned

REGIS·

OF

THE

CAN

FOR

FROM

PANEL.

All

gauges are illuminated

on

and

remain illuminated while

for

PREHEAT

BE
THE

ADMIRAL

is

equipped

with

an

ELAPSED TIME

also includes a

gauge which measures

WATER
GRADUATED

ILLUMINATED
TURNED
TEMPERATURE

WATER

when

two

rubber-booted

and

one

for

TEMPERATURE

ON.

IN

DEGREES

WHILE

THE

ENGINE'S

IS

170·

GAUGE:

THE

-190· F

with

in

hours

TEMPER-

in

degrees

and a DC

the

sys-

the

key

the

engine

START.

THIS

FAHRENHEIT

KEY

SWITCH

NORMAL

(77"

CONTROL

When
the

a

and

the

GAUGE

IS

AND

IS

IS

OPERATING

-

aa·c).

water temperature gauge
temperature reading indicated
power
when
will

once

electrical power
A separate alann

Admiral
necting
electrical
the

buzzer

be

audible
running.
on

and
engine's

PANEL

the

engine

is

was

turned off. The

the

key

switch

again

register

is

restored

buzzer

Panel.

TIle

the

buzzer

to

harness.

The

should

oil

The
in a location
to

the

operator

buzzer

silence

pressure

shut

down

with

the

key

will

continue

by

the gauge before electrical

oil

pressure gauge

is

turned off. The temperature

the

engine's
to

with

installer

the

is

four-pin

installer

where

should

will

sound

when

the

rises

above

OIL

PRESSURE

ATED

IN

POUNDS
ILLUMINATED
ON.

THE

ENGINE'S
PRESSURE
(2.1 -4.2

true

the

gauge.

harness

is

responsible

connection

is

also

responsible

it

will

be

it

sound

when

the

engine

15

psi

GAUGE:

PER

WHILE

NORMAL

RANGES

kg/em').

BETWEEN

temperature

supplied

dry

while

ignition

has

(1.1

THIS

SQUARE

THE

switch

to

register

will

with

for

electrically

on

the

for

and

where

the

key

started

and

kg/cm2).

GAUGE

INCH

KEY

SWITCH

OPERATING

30 -60

turned

the

fall

to

gauge

when

every

engine's

installing

it

engine

is

turned

the

IS

GRADU·

(PSI)

AND

IS

TURNED

OIL

psi

off,

last
zero

con-

will

is

IS

HOURMETER:
REGISTERS
TIME,
USED
THE
SCHEDULE.

PREHEAT
ALTERNATOR'S
FUEL
ENGINE'S
OIL
BUTTON

START
STARTER'S
THIS
UNLESS
AT

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

EXCITER,

SOLENOID

PRESSURE

BUTTON

THE

ON

GLOW

PLUGS.

ALARM

ENERGIZES

BUTTON:

WHEN

SOLENOID

WILL

THE

PREHEAT

SAME

TIME.

BE

FOR

THE

SWITCH.

THE

PRESSED,

WHICH

NOT

BUTTON

PRESSED,

THE

FUEL

INJECTION

IT

BYPASSES

IN

START

BUTTON.

ENERGIZES

CRANKS

OPERATE

ELECTRICALLY

IS

PRESSED

ENERGIZES

liFT

PUMP.

PUMP,

AND

THE

ENGINE'S

ADDITION,

THE

THIS

THE

ENGINE.

AND

THE

THE

THE

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

TO 5 -10

THE·ALARM.

OFF

ALARM:

THE

OIL

psi

~

SYSTEM

ALARM:

THIS

SWITCH

01

L

OIL

kg/em'),

EVENT,

AN

PANEL.

PRESSURE

GALLERY.

SHOULD

THE

INSTRUMENT
EMIT A CONTINUOUS

AN
ENGINE'S
PRESSURE.

(0.4 -0.7

IN

THIS

ALARM

IF

WILL

SIGNAL.
ALARM

THIS

THE

THE

SWITCH

ALARM

SWITCH:
POWER
INSTRUMENT
CLUSTER.

DC

VOLTMETER:
INDICATES
BATTERY
SHOULb

BUZZER

HAS

THE

ENGINE'S

CLOSE

SOUNDING

SWITCH

SWITCH

ENGINE'S

WILL

MONITORS

OIL
WILL

CLOSE

EMIT A PULSATING

PROVIDES

ONLY

TO

THE

PANEL

THE

AMOUNT

IS

BEING

CHARGED.

SHOW

13V

BEEN

COOLANT

THE

IS

PRESSURE

SOUND·

TO

THE

14V.

Engines & Generators

5

DESCRIPTION

This

manually-operated

KEY

switch,

an

RPM

tons,

an

INSTRUMENT

lamps,

one

for

ALTERNATOR

OIL

PRESSURE,

TEMPERATURE.

RPM

GAUGE:

PER

MINUTE
REAR

OF

OFTHE

RECALIBRATED
THE

and

REGISTERS

THE

ENGINE

FOR

ACCURACY

PANEL.

control

gauge,

PREHEAT

TEST

panel

button
DISCHARGE,

one

for

high

REVOLUTIONS

AND

CAN

BE

FROM

CAPTAIN

is

equipped

and

START

and

three

one

ENGINE

OIL
ALARM

COOLANT

PRESSURE

LIGHT

CONTROL

with

a

but-

indicator

for

low

ALTERNATOR
AlARM

LIGHT

PANEL

The

panel

also
PRESSURE
RPM
and

remains

ALARM:
BELOW 5 -10

PULSATING

TEMPERATURE

210°F

(99°C).

NOTE:

THE
SOUNDING
PRESSURE

gauge

THE

ALARM

SIGNAL.

IN

ALARM

IS

NORMAL.

REACHES

or
is
illuminated

psi

IN

THIS

includes

high

COOLANT

illuminated

WILL

SOUND

(0.4 -0.7

kg/cm').

THE

ALARM

THE

FRESHWATER

EVENT,

SOUND

ONCE

15

psi

THE

(1.1

WILL

an

alann buzzer

when

while

the

IF

THE

IN

THIS

WILL

ALSO

COOLING

ALARM

WHEN

THE

THE

ENGINE

kg/cm'),

for

low

TEMPERATURE.

the

KEY

switch

engine

is

in

operation.

ENGINE'S

WILL

THE

OIL

EVENT,

SOUND

KEY

STARTS

ALARM

PRESSURE

THE

ALARM

IF

THE

CIRCUIT

EMIT A CONTINUOUS

SWITCH

COOLANT

RISES

IS

TURNED

AND

THE

ENGINE'S

WILL

SILENCE.

TEST

BunON:
PRESSED,
ALTERNATOR,
PRESSURE,
COOLANT
TURE

CONTROL

CUITS.

WHEN

TH£

ALTERNATOR,

OIL

PRESSURE,

THE

WATER

TURE

INDICATOR
LIGHTS
ADDITION
ING

THE

BUZZER.

OIL

The

is

turned

FALLS

WILL

EMIT

TO

SIGNAL.

ON.

THIS

OIL

WHEN

TESTS

THE

THE

OIL

AND

THE

TEMPERA-

CIR-

PRESSED,

THE

AND

TEMPERA-

ILLUMINATE

TO

ALARM

IN

SOUND-

on

A

START

BUTTON:
STARTER'S
BunON

WILL

PREHEAT

TIME.

BunON

WATER
ALARM

WHEN

SOLENOID

NOT

OPERATE

IS

WHICH

PRESSED

TEMPERATURE
LIGHT

PRESSED,

ENERGIZES

CRANKS

AND

THE

HELD

ELECTRICALLY

THE

ENGINE.

THIS

UNLESS

AT

THE

THE

SAME

Engines & Generators

PREHEAT

BUnON:
ALTERNATOR'S
SOLENOID
GLOW
SURE
GIZES

ON

PLUGS,

ALARM

THE

START

EXCITER,

THE

AND

SWITCH.

WHEN

PRESSED,

THE

INJECTION

BYPASSES

IN

ADDITION,

BUnON.

KEY

SWITCH:

POWER

ONLY
INSTRUMENT
CLUSTER.

ENERGIZES

FUEL

LIFT

THE

ENGINE'S

PUMP,

AND

THIS

THE

BUnON

PUMp,

PROVIDES
TO

THE

PANEL

THE

THE

FUEL

ENGINE'S

OIL

PRES-

ENER-

6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use

2-D

Care

Use

in
ticles
finely
keep
careless handling or improper storage facilities.
that
clean

Purchase a
Install

filter/water separator between
The
filters.

ENGINE

Use a heavy
or
hours
thereafter.
chart:

FUEL

fuel

that

meets

(ASTM),

Of

only clean

your

which

finished

it

the

and

Raycor 500

and

has

The

Fuel

diesel

fuel

injection

might

parts.

clean.

The best

fuel

going

pure,

the

well-known

and

regularly service a

FG

OIL

duty

engine

CG-4

or

better.

Change

of break-in operation,

For recommended

Operating

Above

Temperature

68°F

the

requirements or specification of

a cetane rating of

#45

Supply

fuel!

The clearance of

pump

is

very

pass

through

It

is

fuel

into

the

following practice

brand of

or 900

(20°C)

the

important

can be rendered unsatisfactory

tank

for

fuel.

good,
the

fuel

FG

are

oil

with

an

the

engine oil after

and

every

oil

viscosity,

SAE

critical; invisible dirt

filter

to

your engine's

visual-type

good

API

30,

the

can

buy clean

is

advisable:

tank

and

examples of

classification of

100

hours

see

Oil

Viscosity

10W-30

or

better.

components

damage

fuel,

To

assure

daily

fuel

the

engine.

an

initial

of operation

the

following

or

15W-40

Class

par­these
and

use

such

50

by

is

CF

ENGINE

WESTERBEKE

and

chemicals that can corrode internal engine
The antifreeze performs double

run
the
cooling circuit from rust
quality antifreeze that contains Supplemental
Additives
balanced, crucial

The distilled water
being

NOTE:

antifreeze that

The recommended 50/50 mixture will protect
against
mixture
life of

Coolant

A coolant recovery tank kit
WESTERBEKE

tank

during
without introducing air into
provided

COOLANT

reco~ends

50%

distilled

at

proper temperatures

engine

poured

Look for

the

will

the

is

to

allow

engine operation, without

and

water.

to

the

coolant, and lubricates

(SCAs)

circulating pump impeller

Recovery

that keep

to

long

and

antifreeze should

into

the

cooling circuit. .

the

new environmentally-friendly

is

now

available.

most extreme temperatures. The antifreeze

also

retard rust within the engine

Tank

diesel

engine.

for engine coolant expansion

must be installed before operating

a

mixture

Distilled water

duty.

It

by

transferring heat

and

corrosion. Look

the

antifreeze chemically

term protection.

and

is

supplied

The purpose of

the

loss of coolant

the

cooling

of

50%

is

free

surfaces.

allows

and

be

seals.

with

system.

antifreeze

from

the

the

engine

away

protects

for a good

Cooling

premixed

long

the

engine

and add

each

this

recovery

and

contraction

This

the

engine.

from
the

before

lasting

to

and

kit

to

the

is

41° -68°F

Below

A

CAUTION:

engine

oil
additives
to

Oil

The engine's
by

the
normal
55

psi

NOTE:

reading

an

oil

readings

engine and

of

produce

Pressure

oil

pressure gauge

operation,

(2.5

and

A newly

up

pressure

will

(5 -20°C)

41°F

00

to

mix.

Each

different

properties

oil

pressure,

the

3.9

kglcm2).

started,

to

60

psi (4.2

reading

vary

depending

the

load placed

(5°C)

not

allow
brand

brands

harmful

during

on

oil

pressure will

cold

kglcm

as

the

engine

low

upon

on

SAE

20,

SAE

10W-30

two

or

contains

could

react

to

your

operation,

instrument

can

2

).

A warmed

as

25

psi (1.8

the

the

engine.

10W-30

or

or

15W-40

more

brands

its

own

in

the

engine.

is

indicated

panel.

range

between

have

an

engine

kglcm

temperature

15W-40

of

additives;

mixture

During

35

oil

pressure

can

have

2

).

These

of

the

and

NOTE:

This

tank,

with

its

short
located
can

particular installation makes

at or above

be

located below

the

the

level

level

of

this

run

the

of

of

plastic

hose,

engine's

the

necessary.

manifold,

engine's manifold

is

best

but it

if

the

Engines & Generators

7

PREPARATIONS

PRESTARTINSPECTION

Before starting your engine for

layoff,

prolonged

D Check

at

the

high mark

D

Turn

on
examine
contaminants.

D Check
D Check

and

battery cable connections. Make certain

( +) battery cable

the

negative (-) cable

(this

stud

D Check

and

at

NOTE:

refer

to

D

Visually
parts,
the

threaded connections

o

Make

engine.
performance.

o

Make

D

Ensure
transmission.

D

Open
to

the

check

the

engine

oil

on

the

fuel

supply,

the

fuel

filter/water separator

the

transmission

the

DC

electrical

is

connected

location

the

coolant level

the

manifold.

If

the

the

examine

disconnected wires,

certain there

An

sure

the

the

thru-hull

raw

water

is

engine

COOUNG SYSTEM section

the

is

ample

supply

the

mounting installation

propeller shaft

and

strainer.

the

first

the

following

level.

the

dipstick.

then check

fluid

system.

is

connected

tagged).

in

has

not yet been filled

engine.

and

and

proper ventilation

is

is

make

items:

Add

oil

level.

Inspect

to

the

both

the

Look

unattached

engine

necessary for proper engine

securely attached

certain

time

to

the

starter solenoid

to

plastic recovery tank

for

is

raw

or

after a

maintain

fuel

bowl

the

loose

attachments.

secure.

the

supply
for

wire

connections

the

engine ground

with

coolant,

of

this

manual.

or

missing

hoses.

around

the

to

water

is

level

and

positive

and

Check

the

primed

FOR

INITIAL

START-UP

COOLANT
RECOVERY
TANK

I~_-

OIL

,

PRESS

DIPSTICK

IN

TIGHT

Engines & Generators

8

STARTING • STOPPING

PROCEDURE

STARTING

1.

Place
control

2.

Thrn

(If

3. Press
(The

4.

Release
BUTION. (The starter motor

5. Release

6.

With
proper oil pressure
water temperature
when

NOTE:

engine

It
Become
immediate

PROCEDURE

the

transmission

to

slightly

the

KEY

the

panel

the

PREHEAT

fuel

lift pump

the

the

the engine running, check the instruments

the

thermostat

Never attempt

is

running.

is

important

aware

open.

SWITCH

is

energized,

is

PRESTART

START

action

BUTION

and

will

to

closely

of

the normal engine

if

Temperature/Preheat

Atmospheric

41°F(5°C)

41°F(5°C)

23°F(-5°C)

Limit

NOTE:

The
PREHEAT button
button activates
the

PREHEAT intermittently

plugs.

NOTE:

When

A voltage

when

the

is

depressed.

Temperature

or

higher

to

23°F

(-5°C)

or

lower

of

continuous

START button will not energize

starting:

drop

preheat button

use

is

depressed.

the

glow plugs

will occur

in

neutral

and

advance

to

the

ON

position

the

gauges

are

BUTION,

priming

BUTION

battery charging voltage.

rise slowly

opens.

to

engage

and

the

engine.)

is

cranking

as

the engine

and

the

starter while

hold

and

press the

then stabilize

monitor the panel

readings

these

readings

Depressing

in

to

avoid overheating

start

Preheating

Approx.
Approx.
Approx.

30

seconds

the

cylinder head

unless

the

the

throttle

(2

o'clock).

on.)

for 5 seconds.

START

the

engine).

starts.

for

The

the

gauges.

and take

to

vary.

Time

10

seconds

15

seconds

20

seconds

before

cranking

the

PREHEAT

so

use

the

glow

STOPPING

To

stop

place the transmission in neutral. Allow

few

a
engine

NOTE:

(12 o'clock).

instrument panel will put a

Starting

Make

prevailing

of

CF

FAILURE

If

the

5

seconds,
procedure.
neutral

to

prevent

Never

fails

to

this

manual.

A

the

system

the

cooling

enter

manifold

from

through-hull

correcting

Engine

warrantable

in

mind.

PROCEDURE

the engine, bring

moments

down

Make

certain
or

engine

position

run

start,

CAUTION:

engine
pump

the

happening

to

stabilize temperatures,

by

turning off

certain this key switch

If

the

Under

temperature.

CG-4,

starting
the

the

TO

START

fails
wait
Make

starter

refer

SAE

for

as

Cold

lubricating oil

to

at least

certain

some

in

to

Prolonged

starting

filling

with

is

pumping

system

during

engine's

once

the

by

shutoff,

the

cause

damage

resulting

issue;

the

throttle

the

key

switch.

is

key switch

is

drain

left

on

Conditions

is

appropriate

Use

oil

with

an

30,

lOW-30,

start

when

the
engines

gear.
for

more

the

TROUBLESHOOTING

can

raw

water.

raw

cranking.
cylinders
exhaust

closing

draining

of

the

owner/operator

or

the

start

30

seconds

transmission

have a neutral

then

30

cranking

result

in
This

water

through

by

way
system
the

raw

the

the

excessive

from

raw

the

This

to

ON,

the

15W-40.

exhaust

an

idle

the

engine

then

in

the

OFF

the

battery.

API

Specification

button

and

repeat

control

seconds.

intervals
engine

may

happen

the

raw

of

the

fills.

Prevent

water

supply

engine

water

entry

should

position

to

shut

the

position

energized

for

the

is

pressed

the

starting

is

in

safety

If

the

engine

CHART

without

exhaust

because

raw

water

water

can

exhaust

this

muffler,

cranking.

is

not

keep

and

idle for

for

the
switch

in

and

a

this

Engines & Generators

9

ALTERNATOR

The

Captain

with a red
The

Admiral

performance

COOLANT

A coolant temperature
housing.
coolant's

2100P

(99°C).

WARNINGS

Control

warning

Control
of

the

light.

alternator.

TEMPERATURE

This

switch

operating

temperature

WARNING

Panel

indicates alternator

Panel

uses

LIGHTS,

a voltmeter

SWITCH

switch

is

will

located

activate a

reaches

on

continuous

approximately

low

to

monitor

the

thermostat

alarm

ALARMS & CIRCUIT

LOW

OIL

PRESSURE

discharge

the

if

the

A

low

oil

pressure alarm switch

oil

gallery.
pressure.
(0.4 -0.7

ENGINE

The
mounted
Excessive
the
breaker
because

this
After

Should

kg/cm2),

CIRCUIT

DC

harness

manual

instrument

to

the

should

repairing

This

switch's sensor

the

on

reset circuit breaker (20

current

panel

trip.

In

this

opened

occur,

the

BREAKER

ALARM

engine's oil pressure

this

switch

BREAKER

the

engine

draw

or electrical overload

wiring

event

breaker

check

and

fault,

reset

SWITCH

is

located off

monitors

will

is

protected

or engine

most

engines

disconnects

repair

the

breaker

the

engine's

the

engine's

fall

to

5 - 10

activate a pulsating

by

an

engine-

amps

DC).

anywhere

wiring

will

cause

will

shut

down

the

fuel

supply.

the

source

of

the

problem.

and

restart

2DACIRCUIT
BREAKER

oil

psi

alarm.

in
the

If

the

COOLANT
SENOOR

THERMOSTAT

ASSEMBLY

OIL

GALLERY

Engines & Generators

10

ENGINE

BREAK-IN

DESCRIPTION

Although your engine
hour

of

test operations at the factory
assembly procedures were followed and that the engine
ated

properly,
your engine
and serviced during

Breaking-in a
ton

rings

and

smoky
scored,
break-in period. .

Your

new

conditioning operation

to maximize the performance and service life of the engine.

Perform
lowing:

1.

Start the engine according

DURE

that
charging)

2.

Allow the engine

fast

the

a break-in time

is

dependent upon

new

to

the cylinder
operation indicate that the cylinder walls are

which

is

engine requires approximately 50 hours of initial

this

conditioning carefully, keeping in mind the

section.

all systems

are

idle)

until the water temperature gauge moves into

130 -1400P

has

experienced a minimum of

to

make sure accurate

is

required. The service life of

how

the engine

its

initial 50

engine basically involves seating the

walls.

caused

by

to

Run

the engine at fast idle while checking

(raw

water

functioning.

to

warm

(55

- 60°C) range.

hours

of

Excessive oil consumption

overloading the engine during the

break in each moving part in order

to

the

STARTING

pump,

oil pressure, battery

up

(preferably

use.

is

PROCE-

by

running at

one

oper-

operated

pis-

fol-

PROCEDURE

using

the

3. While
speeds

for

idling.

4.

Avoid

rapid acceleration, especially

5.

Use

caution

grey

or

black exhaust

reach

its

\

6.

During

the

varying engine speeds, with short runs at

Avoid

prolonged idling during this break-in

CHECKLIST

D Monitor
D . Check
D Check

D

NOTE:

break-in

for
for

vibration and blow-back
Confirm

When

the

When

the

When

the

See

the

information

vessel, run the engine

the

first

25

hours.

not

to

overload the engine.

and

full

rated speed

next

25

the

control panel gauges.
leaks of
abnormal noise such

exhaust

engine
engine

engine

smoke:

is

are

hours, the engine

fuel

and engine

sounds.

is

cold - white

is

warm

overloaded -some

TRANSMISSION

on

your

transmission.

Avoid

the

inability of the engine

signs of

- almost smokeless.

section

prolonged

with

an
may

oil.

as

knocking,

smoke.

black

of

at

various

a cold

The

presence

overload.

be

full

period.

friction,

smoke

this

manualfor

engine

periods

engine.

operated

rated

rpm.

and

of

of a

to

at

soot

Engines. & Generators

11

THE

DAILY

OPERATION

CHECK

Follow

D

LIST

this

VIsually

check list each

inspect the engine for

day

before starting your

fuel,

oil,

or water leaks.

en~ine.

D Check the oil level (dipstick).
D Check the coolant level

Periodically check the manifold coolant level.

D Check
D Check your
D Look

D Check
D Check

the

transmission fluid level.

fuel

for

clean fuel

transparent bowl.

for

loose wires at the alternator

mounting

is

secure.

the

starting batteries

in

the coolant recovery tank.

supply.

in

the fuel filter/water separator

and

(weekly).

make sure its

D Check drive belts for wear and proper tension (weekly).
D

VIsually

STARTING

NOTE:

manual

1.

Put

NOTE:

neutral
energizing
transmission
energize.

2.

Tum

[The

3.

Depress

[The fuel lift pump

4. Release the PRESTARr BUITON

BUITON. [The start motor

5. Release the

6.

With
proper

water

opens.

NOTE:

engine

It

is

important
aware
action

inspect the raw water

THE

ENGINE

See

STARTINGISTOPPING

for

more

detailed

the transmission in neutral, throttle advanced.

Hydraulically operated

safety

switch

circuit

is

the

KEY

SWITCH

panel

is

energized,

the PRESTART BUITON, hold for 5 seconds.

START

the

engine running, check the instruments for

oil

pressure and battery charging voltage. The

temperaturewill rise slowly

Never

attempt

is

running.

to

closely monitor the panel gauges. Become

of

the normal engine readings

if

these

readings start

through

passes.

in gear

is

priming

BUITON

to

instructions.

pump

for

PROCEDURE

transmissions

which

the

starter solenoid

This

switch

is

open

so

the

starler solenoid will not

to

the ON position

gauges

engage

to

is

vary.

are

lite}.

the

engine}.

and

cranking

as

the

until

the

starter

and

press the

the

engine starts.

the thermostat

take immediate

leakage.

have a

(2

engine}.

while

in

thi,;,'

when

0'

clock).

START

the

the

FAILURE

If

the
5 seconds, wait for at least
procedure.

neutral

to prevent starting in

Never

fails

this

A

engine
filling
pump
cooling
enter
manifold
from
through-hull
correcting
Engine

warrantable

in

Stopping

To
place
a

few

engine down

NOTE:

position(

energized

TO

START

engine

fails

to

start when the start

Make

certain the transmission control

position

run the starter

to

start, refer to the

manual.

CAUTION:

is
the

happening

starting

with

raw

pumping

system

engine's

once

shutoff,

the

damage

issue;

as

some engines have a neutral safety switch

gear.
for

more

TROUBLESHOOTING

Prolonged

can

result

water.

raw

water

during

cylinders

the

exhaust

by

closing

draining

cause

of

resulting

the

mind.

Procedure

stop

the engine, bring the throttle

the transmission

moments

by

Make

certain

120'

clock}.

instrument panel will put a

in

to

stabilize temperatures. Then shut

turning off the

this

key

If

the

30 seconds

than

cranking

in

This

may

through

cranking.

sytem
the

the

excessive

from

the

by

way

raw

the

raw

and

30

seconds.

intervals

engine

happen

the

This

of

fills.

water

exhaust

water

owner/operator

to

an

neutral. Allow

key

switch.

switch

is

in

key

switch

is

left

drain

button

repeat

exhaust

because

raw

raw

water

the

exhaust

Prevent

supply

muffler,

engine

entry

should

idle

the

engine

the

OFF

ON,

on

is

pressed for
the

starting

is

in

If

the

engine

CHART

without

system

the

water

can

this

and

cranking.

is

not

keep

position

to

idle

the

the

the

battery.

the

in

the

a

this

and

for

Engines. & Generators

12

In

order

sary

to

log

your

record

NOTE:

M0J7.Y

simple

but

expert

knowledge

to

use

this

your engine

engine

of

the

others

Maintenance

hours.

hours

by

following

are

more

difficult

of a service

Schedule,

Use

your

running

time.

maintenance

0J7.d

mech0J7.ic.

MAINTENANCE

it

will

be

neces-

engine hounneter or

SCHEDULE

A

while

procedures

may

require

the

are

equipment
co"ect
terminals
elecuicalequipment

WARNING:

the

tools

engine

such

as

for

when

servicing

Never

is

each

attempt

running.

goggles

and

job.

Disconnect

any

to

Wear

gloves,

of

the

perform
the

proper

and

the

battery

engine's

any

safety

use

DC

service

the

SCHEDULED

MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Transmission

Drive

Visuallnspeclion

Fuel

Starting
(and

Engine

Heat

Fuel/Water
Exhaust

Engine

Throttle

Control
Adjust
Raw

Separator

Oil

Level

Level

Fluid

Belts

Filter

Batteries

House

Batteries)

Oil

and

Filter

Exchanger

Hoses

Engine

Water

Zinc

Separator

System

and

Transmission

Cable

Idle

Pump

of

Level

Engine

Anode

Speed

CHECK

EACH

DAY

D
D

D
D
D
D

weekly

D

D

weekly

HOURS

OF

50

100

250

500

NOTE:

Keep

engine

surface

oil

will

inhibit

the

cool.

D

D

D D D D

engine's

D D D D

D D D D

D D D

D

D D D

D D
D D
D

D D

OPERATION

750

1000 1250

clean.

Dirt

ability

to

D D D
D D D

D

D D
D D

and

remain

D

D D

D

D

MAINTENANCE

Diesel

No.2

Check

for

water

necessary).
Oil

level

should

dipstick.
Check

at

recovery

Add

coolant

Fluid

level

should

on

dipstick.

Inspect

for

proper

and

adjust

if

Check

for

fuel,

and

electrical

Check

for

loose

Clean

with

kerosene

100

hours.

Change

Check

electrolyte

and

make

sure

excessive

Initial

change

Inspect

exchanger
Change

Initial

Inspect
operation.
and/or
clean
connections

Hose
spongy.

Check

Lubricate
Adjust
Remove

gasket,
seals

corrosion.

engine

both
zinc

anode,

end

filter

check

at

for

leaks.

Check

corrosion

and

replace

should

Check

for

loose

with

to

750

the

cam

and

and

shaft

rating

of

45

and

dirt

indicate

between

tank;

if

if

needed.

indicate

tension

needed.

Check

oil

and

water

connections.

belt

tension.

at

50

at

500

levels

every

connections

oil & filter

every

every

50

are

be

WD-40

-1000

pump

change

100

hours.

replace

of

zinc

anode

200

hours.

hours,

Check

anti-siphon

the

exhaust

buildup

as

necessary.

tight.

Check

hard & tight.

and

tighten

fittings,

cotter

or

rpm

cover

cover

for

drive

tang.

DESCRIPTION

cetane

or

higher.

in

fuel

(drainlreplace

MAX.

and

empty,

check

at

between

(3/8"

hours
hours.

then

on

equivalent.

and

wear.

to

belt

edges

leaks.

Keep

bolts & nuts

then

50

are

very

at

if

needed.

debris.

every

elbow

inside

Check

casting

Replace

all

hose

pins,

inspect

Check

MAX

1/2'

deflection)
for

Inspect

clean

operating

tight.

50

hours,

Clear

250
valve

for

carbon

passages;

that

integrity.

if

soft

clamps.

etc.

the

the

filter

if

lOW

on

manifold.

and

LOW

wear.

wiring

tight.

every

hours

Clean

off

then

the

heat

hours.

all

or

impeller,

bearings,

(continued)

Engines & Generators

13

NOTE:

Use

engine

hours

MAINTENANCE

the

engine

by

running

hourmeter

time.

gauge

SCHEDULE

to

log

your

engine

hours or

record

your

SCHEDULED

MAINTENANCE

Coolant

System

Air

Cleaner/Silencer

DC

Alternator

Transmission

Engine
Damper

*Fuellnjectors

*Starter

*Preheat

*Engine

Compression

*Adjust

*Heat

Lubricate
with

"Lockeze"

Transmission
Fluid

Oil

Transmission

Plate

Motor

Circuit

Cylinder

the

Valve

Exchanger

Panel

Cooler

Clearances

Key

Switch

CHECK

EACH

DAY

HOURS

OF

OPERATION

100

250

500

750

50

1000 1250

0

0 0 0 0

0

0 0 0
0 0

0

0 0

0 0

0 0

0 0 0

0 0 0 0 0

0

0 0

0

0

0
0

0

0 0

Drain,

flush,

appropriate
Every

100

Check

DC

bracket;

Remove;

tested.

Chattering
of

damper

Check

and

spray

condition

Check

solenoid

and

lubricate.

pinion
Check

clean

glow
element
compound

Check

compression

Adjustments).

Adjust

Valve

ADJUSTMENTS).

Remove,

tested.
At

0

first

Initial

300

fluid

hours

MAINTENANCE

and

refill

antifreeze

hours,

inspect,

charge

from

tighten

electrical

have

professionally

at

idle

and

plate

wear.

adjust

injection

(see

ENGINE

and

motor

Clean

and

drive.
operation

100

of

plugs,

(X-X

ohms).

on

threads.

Clearances

have

professionally

hours,

change

or

at

winterizing.

preheat

check

pressure

then

at

DESCRIPTION

cooling

system

mix.

clean,

replace

alternator.

low

Remove

lubricate

resistance

Reinstall

(see

each

25

Check

connections.

cleaned

rpms

is

and

opening

ADJUSTMENTS).

for

corrosion.

the

solenoid.

with

and

timing

ENGINE

cleaned

year

hours,

then

with

as

needed.

mounting

and

pressure

an

indication

replace.
pressure

Remove

starter

Remove

value

of

anti-seize

(see

and

pressure

at

winterizing.

every

and

motor

and

heater

Engine

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

14

mechanic.

FUEL

FILTERJWATER

A primary
installed between
water
be

carried

Most installers include a

installation package
contaminants in the

A typical
is

the Rayeor

separator type filter

tank and engine-mounted

will
equipment.
certain the

free

and

fuel

filter of the water separating type must

the

fuel

and

other contaminants from the

to

the

fuel

system

as

they

fuel

fuel

filter/water separator

Model

500

is

not installed between the

affect the

of impurities.

maintaining a proper

fuel

pump,

The

owner/operator

fuel

reaching

This

process

SEPARATOR

tank and the engine

on

the engine.

fuel

filter/water separator with

are

aware of the problems that

can

cause.

is

illustrated

MA.

Keep

in mind that if a water

fuel

system,

engine

filter,

is

responsible

the

engine's injection equipment

is

accomplished by installing

fuel

filter/water

fuel

before

any

water in the

and

injection

separator.

to

for

FUEL

remove

they

below.

fuel

supply

making

be

can

the

This

fuel

SYSTEM

FUEL

The
manufactured and they must receive clean diesel
from water
must
separator and the engine's spin-on
clean, and change these
schedule in this manual.clean, and change these
according

is

FILTERS

fuel

injection pump and the

and

dirt.

pass

through at least

to

the maintenance schedule

A

WARNING:

when

servicing

any

fuel

that

may

To

ensure this

two

filters

Shut

off

the

fuel

system.

spill. . .

fuel

injectors

flow

fuel

filters, a fuel

fuel

according

the

fuel

Take

are

of clean

filter.

Visually

to

the maintenance

in

this

manual.

valve

at

the

care

in

precisely

fuel,

free

fuel,

the

fuel

filter/water

inspect,

filters

tank

catching

FUEL

FILTER!

WATER

[Owner

FUEL

Periodically check the
pump and
fittings
one
secured by
operations.

When energized
will
flow

SEPARATOR

Installed]

LIFT

PUMP

fuel

make

sure

that

are tight and secure. The

of

the pump's mounting bolts should

the

mounting bolt

thru the preheat circuit,

purge

air

from

the

fuel

of

fuel

as

the

engine

connections

no

leakage

to

system and provide a continuous

is

running.

to

and out of the

is

present and that

DC

ground connection

be

clean

and

ensure proper pump

the

fuel

lift pump

TO

FUEL

well

FILTER

the

at

"'-~U;l\L.11111

LIGHTLY

Changing

1.

Shut off the

2.

Loosen the
filter
proper disposal.

Using a

3.
bracket

4.

Lightly oil the sealing gasket
reinstall, tum the filter assembly counterclockwise care­fully
housing bracket. Turn

5. . Twn
preheat function should quickly prime the system and

engine should start.

FUEL

The

fuel
diesel engine, requiring the utmost care in handling. The
injection pump
owner-operator
requires servicing, remove it and take it
injection pump service
disassemble and repair

The only adjustment the servicing mechanic should
the

fuel

speed

ADJUSTMENTS.

the

wrench. Place the used filter in a container

rag,

so

the

until the gasket contacts the sealing surface of

on

the

INJECTION

injection pump

injection pump

(see

IDLE

WIPE

WITH

CLEAN

FUEL

Fuel

Filter

fuel

supply.

fuel

filter,

turning counterclockwise

wipe clean the sealing face

new

filter can

fuel

supply and start the

be

seated

on

the

new

213

further with the filter

engine.

properly.

PUMP

is

a very important component of

has

been thoroughly bench-tested and

is

cautioned not to attempt

to
facility.
it.

SPEED

Do not attempt

is

the adjustment

ADJUSTMENT under ENGINE

for

on

the housing

filter.

The

to

service

an

authorized

to

engine idle

with

for

To

wrench.

normal

the

it.

make

a

the

fuel

If

fuel

GASKET

the

the

it

to

Engines & Generators

15

COOLING

SYSTEM

DESCRIPTION

Westerbeke

fresh

tion

and
circulates throughout the engine. This circulating fresh water
coolant cools the engine

the

engine
fresh
exchanger,

water

fresh

ferred
tube

exhaust system where

other

coolant

transferred heat overboard through the exhaust system. The
fresh

each

allows
harmful deposits.

FRESH

NOTE:

recommended

fresh

Fresh water coolant
lating
tIlen
heat exchanger where it
block via the suction side of
engine
the

closed thermostat (although some coolant

bypassed around the thermostat
fold
stat gradually opens, allowing
coolant
cooling

Coolant

A coolant recovery tank allows for engine coolant expansion
and

contraction during engine operation, without

cant loss of coolant and without introducing air into the cool­ing system. This tank should
engine manifold

NOTE:

sure
good

closes

marine engines are designed and equipped

water

cooling. Heat produced in the engine

friction

water

flows

water

to

walls

words,

is

water

other.

the cooling water passages

WATER

Refer

water

pump,

paSses

is

from

to
system.

Periodically

cap.

condition

tightly.

is

transferred

oil.

The heat

coolant

similar in function

coolant

the fresh water coolant

to

cooled

coolant and

Using only fresh water coolant within

to

raw

through the tubes of the heat exchanger while

flows

the

raw

water which

finally

the engine

by

raw

COOLING

to

the

ENGINE COOlANT

antifreeze

to

fresh water coolant which

block,

its internal moving parts,

is

transferred externally from

water

by

means of a heat

to

an

automotive

around the tubes; engine heat trans-

is

conducted through the

is

then pumped into the

it

is

discharged overboard. In

is

cooled

by

fresh water coolant, this

water,

and

the

raw

raw

water circuits

to

stay clean and free from

CIRCUIT

section

and

water

mixture

coolant.

is

pumped through the engine

absorbing heat

through the thermostat into the manifold,

started cold, external coolant

overheating).

flow

unrestricted

Recovery

level

check

Ensure

that

and

check

Carry a spare

from

the engine. The coolant

is

cooled, and returned

the

circulating

to

prevent

As

the engine

full

flow

to

the

external portion of the

Tank

be

located at

and

should

be

the

condition

the

upper

and

that

the

vacuum

cap.

flow

warms

of

easily accessible.

of

lower

by

combus-

the

radiator.

water carries the

are

independent of

the

engine

for

the

to

be

used

as

by

a circu-

to

to

the engine

pump.

When

is

prevented

flow

is

the

exhaust mani-

up,

the thermo-

the

engine's

any

signifi-

or

above

the

the

manifold

rubber

seals

valve

opens

for

and

Raw

the

the

the
by

pres-

are

and

in

CHANGING

The engine's coolant must

MAINTENANCE

become contaminated, it

A

criticalj a substantial
traced

Drain
engine block and opening the manifold pressure
the

system

NOTE:

be

used

A

Wear

Refilling

After replacing the engine block drain plug, close the heat
exchanger's coolant petcock. Then run the engine at idle
slowly

NOTE:

When
the

petcock

Monitor
the manifold
sure

cap.

Remove the
coolant mix
the

cap.

flow

into the recovery

After checking
Coolant should
engine cools

needed.

RECOVERY

FROM

RECOVERY

COOLANT

be

changed according

SCHEDULE.

CAUTION:

back

the

engine coolant

The

to

WARNING:

protective

pour clean, premixed coolant into the manifold.

Open

a steady

the

Run

Clean

mCOOLANT

COOLANT

Proper

to

cooling

with fresh

drain
help

water,

petcock on

drain

engine

Beware

gloves.

the

Coolant

the

air-bleed petcock on

flow

of

coolant

and

fill

the

system

coolant in the manifold and add

to

the filler neck

cap

on

the coolant recovery tank

to

halfway between

the

engine and observe the coolant expansion

tank.

for

leaks, stop the engine and

draw

back into the cooling system

down.

Add coolant

up

any

spilled coolant.

TANK

TANK

If

the

coolant

can

lead

to

overheating

cooling

number

system

by

system

of

engine

corrosion.

loosening the drain plug

then start the refill

the

heat

exchanger

coolant.

of

the

hot

engine

the

heat

appears

until

and

at

the

manifold

install the manifold

LOW

and

to

the

recovery

KEEP

THE

COOLANT

CLEAR

to

is

allowed

problems.

maintenance

failures

cap.

process.

should

coolant.

exchanger.

the

petcock,

remains

as

needed.

and

fill

MAX

and

allow

as

tank if

PASSAGE

PRESSURE

the

can

on

Flush

close

pres-

with

replace

it

to

the

is
be

also

Fill

cool.

/CAP

to

the

and

full.

THE

ENGINE

JUST

OIL

FILTER

COOLANT

ON

THE

ENGINE

TO

THE

IS

LOCATED
BLOCK
OF

THE

j"""'WESTERBEKE

,

Enain~s

~

Generatars

16

DRAIN

RIGHT

COOLANT

RETRACTION

COOLING

SYSTEM

THERMOSTAT

A thennostat,
engine,
continuously
the

engine
coolant
hole

in
overheating).
gradually

checked,

and

gasket

Replacing

Remove
housing
gasket,
gasket before pressing it into
cap

screws.

Run

the

are

there

located

controls

from

the

flows

is

first

flowing

thennostat

As

opens.

cleaned,

the

the

The

the

the

cap

screws

as

shown.

apply a thin

engine

and

no

leaks

near

the

coolant temperature

through

started,

the

(some

to

prevent

engine

thennostat

or replaced

Thermostat

and

When installing

coat of sealant

check for nonnal temperatures

at

the

tbennostat housing.

manifold

the

closed cooling

closed thennostat

coolant

warms

easily.

disassemble

place.

at

as

is

by-passed

the

exhaust

up,

the

is

accessible

Carry a spare

the

new

on

both

Do

not over-tighten

the

the

front

of

the

coolant

circuit.

prevents

through

manifold

thennostat

and

can

thennostat

thennostat

thennostat

sides of

When

be

the

and

the

a

from

and

the

that

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A clean
engine's cooling

strainer

in

the

glass

Perfonn

operation:

1. Close the raw water seacock.

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open the seacock.

7.

Run

NOTE:

Also follow

aground.

If

the

engine temperature gauge ever
nonnal reading,
may

have

raw

water through

INTAKE

raw

water intake strainer

system.

when

making your periodic engine

should

the

following maintenance after

and

clean

the

glass.

the

washer

and

the

engine

the

been

caught

STRAINER

the

strainer at or below

Include a

be

clear.

the

strainer

if

necessary.

install the

and

check

for

the

above procedure after having

cause

may

up

in

the

the

cooling

strainer.

be that silt, leaves or

strainer,

system.

the

waterline

is

a vital component of

visual

inspection of

check.

every

100

filter.

leaks.

shows

a higher

slowing

the

The

hours

run

than

grass

this
water

flow

so

the

of

hard

of

mo:{

TEMPERATURE
SENDER

GASKET

.

STRAINER.
FILTER

TYPICAL

RAW

{Owner

WATER

Installed]

INTAKE

STRAINER

Engines & Generators

17

COOLING

RAW

WATER

The

raw

impeller

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

strainer.
through the raw water pump
the heat exchanger tubes) where it cools the engine circulat­ing fresh water coolant. The raw water
into the water-injected exhaust
ing the exhaust gases. This mixture of exhaust
water

is

discharge pressure.

RAW

WATER

The

raw
non-ferrous housing and a Neoprene
has

flexible

within the impeller housing, producing

On

no account should this pump

always

be

(an

impeller kit).
when lubricant
operation.
are

cautioned

up.

The

broken or tom impeller blades. See MAINTENANCE

SCHEDULE.

NOTE:

Should a failure occur

(seals

and

purchase a new

spare.

COOLING

water

flow

pump.

This pump

The raw water passes from

discharged overboard by the engine's exhaust

CIRCUIT

is

created by a positive displacement

draws

water directly

to

the heat exchanger (through

is

elbow,

mixing with

from

to

the

strainer

then discharged

gas

the

the

and

and

PUMP

water pump

blades which wipe against a curved cam plate

a spare impeller and impeller cover gasket aboard

Such

raw

water pump should

bearings),

Raw

(raw

failures

to

make sure

pump

is

a self-priming, rotary pump with a

impeller.

be

run

water pump impeller failures occur

water)

is

not present during engine

are

not warrantable, and operators

raw

water

flow

be

inspected periodically for

with

the

pump:SO

it

may

be

more

cost efficient

and

rebuild

the

original pump

The

the

pumping action.

dry.

There should

is

present at start-

internal parts

impeller

to

as

cool-

raw

gas

a

raw

SYSTEM

ChangiWJ

Close the
and,
impeller out
Move the blades
push the impeller into the pump's housing. When
assembling, apply a thin coating
and gasket. Open the raw water intake

A

impeller,
the
exchanger.

the

Raw

raw

water intake valve. Remove the

with

the

aid

of

of

the

to

CAUTION:

they

must

cooling

circuit.

ALIGN

SLOT

WITH

IN

Water

two small screwdrivers, carefully

pump.

conform

If

any

be

They

RAW

THE

THE

SHAFT

Pump

Impeller

Install the

of

the

located

often

WATER

new

to

the curved cam plate and

of

lubricant

valve.

vanes

bave

to

prevent

can

be

PUMP

impeller and

found

pump

to

the

impeller

broken

off

blockage

in

the

cover

pry

gasket.

the

in

heat

the

AIR

INTAKE

The replaceable canister contains a paper element that should
be inspected often. Dirt in the element can
cleaned with compressed
greasy or black with
a spare.

NOTE:

continuous.

and

black

FILTERISILENCER

air,

dirt,

the

To

operate

efficiently a diesel

volume

e:fhaust

of

smoke

clear

are

be

shaken off or

however, if the element

canister must

air.

Hard

all

symptoms

engine

starting,

be

replaced, carry

must

an

of a restricted

is

intake

erratic

a

idle,

air

intake.

AIR

INTAKE

FILTERJSILENCER

RAW

WATER

WHEN
THE

IMPELLER

KEY.

FOLD
EITHER
THE

CORRECT

PUMP

l

'.'

INSPECTION:

/

EACH

KEYWAY

THE

IMPELLER

POSITION

REPLACE
ARE

(THEY

/

IN

INSTALLING:

DIRECTION

STARTS).

BLADE

ANY

TAKE

CARE

WITH

WHEN

APPLY

AT

CHECK

BY

BENDING

THE

IMPELLER

CRACKS.

TO

ALIGN

THE

SHAFT

BLADES

IN

WILL

TURN
THE

LIQUID

SOAP

ASSEMBLY

IN

AT

THE

IF

BASE

OF

VIGOROUSLY.

THERE

Engines & Generators

18

Zinc

Anode

A

zinc

anode,
within

circuit
zinc

anode

place

in

the

effects

of electrolysis

The

condition

and

the

anode

should

be

NEW

NOTE:

Electrolysis action

installation

or pencil,

the

is

to

sacrifice

raw

water cooling circuit,

of

is

located

heat

exchanger.

them

on

other

the

zinc anode should

cleaned or replaced

carried

on

board.

REPLACE

ZINC

ANODES

is

the

and

vessel location; not that

in

the

raw

The purpose of

to

electrolysis

thereby

components

be

as

required.

REPLACE

result

of

each

of

COOLING

water cooling

having

action

taking

reducing

of

the

checked

Spare

CLEAN
REUSE

particular

the

engine.

the

system.

monthly

anodes

AND

the

SYSTEM

If

the

zinc

anodes

need

replacement,

which

the

zinc

anode

is

threaded

ening

the

anode

with

another

boss

from

possibly tearing off
removing
poor
the
clean
exchanger
aged
to

ber),

NOTE:

do

insulate
ing

Heat

After approximately

and

motive

exchanger.)

NOTE:

that a heat exchanger cleaning
every

the

zinc,

note

the

condition, there

exchanger.

the

inside of

end

when

removing

your

engine model's heat exchanger end

O-ring

and

The

threads

.not

require

the

zinc from

preventing electrolysis action

Exchanger

Remove

all

gasket

cover,

of

sealant.

Service

are

probably

the

zinc

in

case

the

end

and

the

zinc

Sealant should not

the

1000

pressure test

radiator

Operating

1000

shop

hours.

the

engine's heat

should

in

silty and/or tropical waters

with a wrench

wrench.

the

exchanger

condition

a lot of

end

of

the

debris.

Always

the

present

cover.

install a new

anodes

metal

of

the

on

hours

of operation,

exchanger.

be

able

be

peiformed

hold

the

hex

This

prevents

shell.

of

it.

If

the

zinc

flakes

heat

exchanger

have a spare

one

becomes

Replace

the

gasket

zinc

anode.

are

pipe

threads

be

used

heat exchanger

the

zinc.

remove,
(A

to

clean

and

may

more

boss

while

the

After

zinc

gasket

part

as

local
test

require

often

into

loos-

hex

is

in

within

and

heat

dam-

(refer

num-

and

it

may

hous-

clean

auto-

the

heat

than

COVER
SECURING
BOLT

INSPECT
BOTH

ENDS

ZINC

ANODE

DO

NOT

USE

ON

THE

SEALANT

THREADS

HEAT

NOTE:

When

installing

sure

that

the

end cover securing bolt's sealing a-ring
installed.
end plate failure/sea water

Failure

to

install

EXCHANGER

the

heat exchanger end

this

sealing a-ring

leakage.

~IR

~PETCOCK

BLEED

?-I;~

covers.

Be

is

can

result

in

Engines & Generators

19

ENGINE

1.

2.

OIL

CHANGE

Draining the Oil Sump. Discharge

the

sump

drain hose (attached

while

the

engine

is

warm.

Drain
replace
securely.

NOTE:

is

Always
yellow/gray emulsion indicates
the
prompt attention
qualified mechanic should water
Raw
the

circuit into
is
poor location

Replacing the Oil Filter.

filter

the

hose

in

its bracket,

Thread

size for

114

NPT.

observe

oil.

Although

water present

exhaust system attached

siphoning of

often

filter,
in

the

the

oil
helps
should

NOTE:

to

Place
filter

when

(Oil

or
cooling
oil

filter
sealing gasket comes off
rubber
bracket,

raw

the

caused

or

you

may

upper

and

from

it into a container before

to

lessen spillage. A small automotive

be

helpful

Do

not punch this hole without first loosening

make certain it

some

paper

unscrewing it

any

other

ability.

as

it

is

sealing

gently

the

the

used

this

condition

to

prevent serious damage.·Call a

in

the

water through

exhaust,

by

the

absence

lack of maintenance.

find

it helpful

lower portion of

in

removing

towels

fluid

on

Keep

your

removed

gasket

remains

remove

lube

oil

oil

filling

When

can

and

to

the

to

with

it.

ENGINE

the

used

oil

to

the

front of

the

used

and

replace

oil drain

as

it

is

removed.

the

presence of water

is

rare,

be

present

can

be

the

to

the

engine and/or a

the

raw

the

engine.

of

an

anti-siphon

removing

and

cleaner
the

the

old

be

removed.

a plastic

catch

any

engine

reduces

engine clean.) Inspect

make

sure that

the

old oil

sealed against

the

oil

completely,

the

end

hose

capped end

A

it

does

require

in

the

result of a fault

water cooling

This

the

used

to

punch a hole

old

filter

to

removing

filter

oil

filter.

bag

around

oil

left

in

the

the

rubber

filter.

If

the

LUBRICATING

When

installing

through

engine)

cap

in

oil.

problem

valve,

oil

drain

it.

This

wrench

the

the

the

filter.

engine's

the

old

this

filter

in

its

gasket's sealing surface
apply a thin
on

the

new

filter

nipple

filter

firmly

NOTE:

The

through

A

passages in

WARNING:

contaminants.
and

nails

thoroughly
discard
used

3.

clothing

oil

properly.

NOTE:

Generic filters
material standards or diameters
generic parts might
parts.

Immediately after

run

the

engine

and that

Filling the Oil Sump.

cap

on

the

After

refilling,
checking
around

the

stop

the

engine.

lube

oil

dipstick.

the

dipstick,

OIL

the

new

on

coat of clean engine

oil

filter.

Screw

on

the

oil

filter

by

hand.

engine oil

Avoid

there

top

the

oil

new

should

~

,

is

c.ooled

the

oil filter bracket

Used

engine
prolonged
using

or

rags

containing

are

be

entirely different from

to

make

sure

are

no

oil leaks around

Add

of

the

engine or

run

the

engine for a

pressure. Make sure there

oil filter or

Then check

Fill

to,

the

engine require additional

O~

~

/.

~

~

oil

filter

element,

the

bracket

oil

the

filter

bracket,

by

engine coolant flowing

oil

contains

skin

soap

and

used

not

recommended,

of

an

oil filter change

the oil pressure

new

oil

through

from

the

the

quantity of

but not over

wipe

free

of

to

the

rubber gasket

onto

the

and

then

housing

harmful

contact.

water.

Launder

oil.

important items

the

new oil

through

the

side

few

moments

is

oil

drain

oil

the

high

II\~

~

0))1r~

"

.,

A~

the

oil

and

threaded
tighten

assembly.

Clean

Discard

as

the

genuine

and

oil

is

normal

filter.

the

oil

filler

oil

fill.

while

no

leakage

system,

with

mark

oil.

filter

oil

the

skin

or

on
fill,

and

the

on

REMOVE

USING

AN

BMM

(77/76')

TO

DRAIN

THE

OIL

OR

OIL

UP

THRU

THE

PUMP

HOSE.

OIL

SOCKET

THE

WARMED

DRAIN

11/16"0.D.

~~I~~i::t~~

HOSE

~bi~_

OIL

FILTER

Engines & Generators

20

·"·~d""

ASSEMBLY

SPIN

ON

APPLY

WHEN
TURN

FILTER

CLEAN

ENGINE

INSTALLING

ON

HAND

TIGHT

OIL

INSTALLATION

This

popular

ter

from

engine

NOTE:

instructions

To

install,
WESTERBEKE's remote
install

Contact

accessory

the

engine

to

room

bulkhead.

Refer

to

ENGINE OIL CHANGE in this manualfor

on

removing

simply

remove the engine

this

kit

with

the

your

WESTERBEKE dealer

is

a more convenient location

oil

used

the

oil

filter

REMOTE

to

relocate

oil

filter.

fllter kit

facing

oil

as

down

for

the

fllter

shown.

more

OIL

engine's

such

.

and

thread

Always

as

illustrated.

information.

FILTER

oil

fil-

as

an

on

(OPTIONAL)

NOTE:

Westerbeke

incorrect

installation

A

CAUTION:

rectly.

If

pass

valve

from

reaching
failure.
immediately

If

the

in

there

is not

oil

the

the

and

of

It

is

flows

filter

engine

is

no

check

responsible

the

Remote

vital

to

install

in

the

reverse

assembly

causing

oil

pressure

the

hose

for

engine

failure

Oil

Filter.

the

oil

lines

direction,

will

prevent

an

intemal

reading,

the

the

engine

shutdown.

conlnelJ:tiolIS.

cor-

by-

oil

due

to

THE

OUT

CONNECTION

MUST

ATTACH
CONNECTION
REMOTE

OIL

AT

FILTER.

TO

THE

THE

APPLY A THIN

INSTALLING
TIGHTEN
CONTACTS

HOSE

IN

COAT

THIS

KIT.

AN

ADDITIONAL

THE

BASE.

OF

CLEAN

OIL

TO

THE

O-RING

THREAD

THE

KIT

TURN

ON,

AFTER

THE
MUST
CONNECTION

3/4

J;:;p~~---AI:Mn'TI:

WHEN

THEN

HAND

THE

O-RING

IN

CONNECTION

ATTACH

AT

OIL

FILTER.

TO

THE

HOSE

THE

OUT

.

APPLY A THIN
GASKET

.

CONTACTS

WHEN

THE

COAT

OF

CLEAN

INSTAlLING.

BASE,

TIGHTEN

OIL

TO

AFTER

IT

AN

THE

FILTER

THE

FILTER

ADDITIONAL

Engines & Generators

21

WATER

HEATER

CONNECTIONS

WESTERBEKE
on-board hot water
engines

tank, heating

hot water (coolant)

provides easy

system.

the

fresh water

engine.
The water heater should

in

either
that
run
trap

Hoses
heater
heater
then

fitting

a high or

the

connecting

in

a reasonably direct line without

air.

should rise continuously
to

the

to

the

an

air bleed petcock must be installed

on

the

low

position

hoses

engine

so

that air will rise naturally

engine.

If trapped air

heater for bleeding air

access

for

These connections

to

flow

to

the

and

then

cycling back

be

mounted

from

in

relation

the

from

is

in

heater

their

able

while

TO

CONNECT

TO

connecting

ships

to

allow

for

hot water

to

the

an

the

a convenient location

to

the

engine,

so

to

the

engine

can

any

loops

which

might

low

THE

point at

to

rise

at

the

filling

WATER

the

from

the

to

the

heater,

higher

the

system.

HEATER

NOTE:

An air bleed petcock
exchanger and
petcocks
to

NOTE:

engine:SO
pressurized
must

Tee

ing

the

and

expansion

when

escape.

If

Close

any

portion

closed cooling system pressure

(aluminum)

be

installed

the

remote

the

higher

heater;

and plumb a single

the

other back

tank
coolant level
tank will

now

on

the

filling

both tightly after all

in

expansion tank

of

the

to

in

a convenient location

can

easily

serve

as

is

thermostat

the

engine:SO

of

the

heating circuit

remote

the

circuit

two

connections for

the

engine:SO

be

checked.

a check and system fill

plastic coolant recovery tank

expansion tank

kit

is

installed, since this tank serves the

same function.

':~

DISCONNECT

AND

ATTACH

THIS

THE

THE

COUPLING

EXISTING

HEATER

HOSE

HOSE

located

on

housing.

coolant system

the

cap,

expansion

to

become

into

the

heater

line

up

to

return.

so

The

the

engine:SO

Open

air

is

rises

then

tank

the

highest

circuit,

the

return

the

tanks

Install

the

remote

these

to

removed.

above

a

(Kit

location

the

fresh water

expansion

point.

is

not used when the remote

AT

heat

allow air

the

#024177)

point.

choos-

Tee

at

remote

The

REMOVE

THE

EXISTING

BY-PASS

HOSE

DISCONNECT

AND

ATTACH

TO

THIS

FITTING.

THE

EXISTING

THE

HEATER

HOSE

HOSE

Engines & Generators

22

TACHOMETER/HOUR

The

tachometerlhour

ment

panels

contains
common
other
volts
on

The
from

tachometer
the
volts

The
a
meter.

Hour

Check
terminals.

1.

2.

Tachometer

Check
terminal

1.

2.

3. Check

4.

Tachometer

1.

2.

3. Check

ground.

the

tachometer.

alternator charging voltage supplied

the

back

of

the

tachometer

one

alternator

DC.

following

fault

in

meter

for

Voltage
Voltage

nections
terminal

circuit operates on

of

the

diodes

input terminal while the engine

producing battery charging voltage

are

either

of

Inoperative

the

proper DC voltage between (+)

present - meter is defective - repair
not

present - trace (+) and

for

fault.

to

verify the operation.) ,

Inoperative

for

the

proper

and

(-)

terminal with the engine

Voltage
tion

AC
output

ground.
Check electrical connections from tachometer input

minal

present - attempt adjusting meter

access

hole.

voltage

not

voltage.
for

AC

to

alternator connection.

Sticking

Check

for

proper

nal

and

(-)

terminal.

Check

for

good

minal

and

alternator.

that

alternator

alternator pivot bolt

METER

meter used
two

One

circuit operates the

The hour meter circuit

instrument.

in

procedures
the

two

(Jump

AC

voltage between tachometer input

No

results, repair

present - check

voltage at tach terminal

AC

voltage between ''tach inp."

ground connection between meter

is

in

propulsion

separate electrical

AC

the alternator

to

follow

circuits in a tachometerlhour

12

volts

for

well grounded

circuits

hour

operates

to

·the

voltage

and

supplied

is

running,

when

troubleshooting

and

(-)

electrical

DC

to

meter ( + )

running.

through

or

replace

proper alternator DC

on

alternator

to

engine block at

TACHOMETER

NOTE:

Current

dial

to

engine

instru-

with

a

meter and the

on

12

(+) terminal

6-8

volts,

fed

to

the

and

13.0-14.8

(-)

or

replace.

con-

calibra-

meter.

to

ter-

termi-

(-)

ter-

set

calibrating

IDLE

SPEED

&

TACHOMETER

Checking

NOTE:

In a new
the tachometer
engine:S­installations.

1.

Warm

Remove
cloth

pulley

2.

Start and

Aim

3.

confirm
tachometer
using the instrument calibration pod
the instrument

reading

4. Adjust
specified

Normal

model

the

tachometer

screw

tachometers

is

then

to

used for fine

use a coarse

the

crankshaft pulley

tuning.

ADJUSTMENT

CHECK

the

idle

speed

installation having new instrument

may

not always

rpm

This

calibration should

up

the

engine

any

specks

and

place a piece of suitable reflecting

to

facilitate use of a photoelectric type

idle

the engine.

the

light

of the tachometer

the

engine speed. Check the instrument

reading.

panel

as

the

engine.

the

idle speed if

value.

idle speed

(New

Installation)

be

correctly

be

to

normal operating

on

the

crankshaft pulley

onto

Adjust the tachometer in

tachometer

the

is

690-950

into

engine speed

RPM.

calibrated

checked

temperature.

the

reflecting

as

needed

the same

is

adjustment

rpms.

panels,

to

in

all

new

with a clean

tape

on

tachometer.

tape

panel

the

panel

to

bring

rpm

not

within

The

the

the

to

by

the

Tachometer

a.

With
pulley
front

b.

Adjust
driver
the
indicated
idle

Inaccurate

a hand-held tach

retaining nut or with a strobe-type

crankshaft pulley rpm at idle.

the

tachometer with a small Phillips

through

tachometer.

and

at

by

the

the

high

on

the front of

calibration access

Zero the tach and bring it

strobe or hand tach.

speed,

the

crankshaft
tach,

hole

in
to

(Verify

type

the
the

the

read

the

screw-

rear

of
rpm
rpm

at

Engines & Generators

23

ALTERNATOR

The charging system consists of a
with a voltage regulator,
mounted
cables. Because of

electronic voltage regulator

internally or

#14

PINK

'14

BLUE=

DC

circuit breaker

the

on

the

back of the alternator.

114GRAY==~=~-_

~~~~~~~Eii~

DC

ELECTRICAL

DC

belt driven alternator

an

engine

DC

wiring harness, a

and

a battery

use of integrated circuits (IC's), the

is

very

with

compact

connecting

and

is

mounted

SYSTEM

1.

Start

the

engine.

2.

After

the

engine
starting battery voltage at
multimeter set

a.

If

the

tor

is

to

"Checking

b.

If

the
exists
continue

on

voltage

working;

voltage

with

either

with

MULTIMETER

has

run

for a few

the"battery

DC

volts.

is

increasing

omit Steps 3 through 8

the

Service Battery"

remains

Steps

around

the

alternator

3 through

minutes,

toward

12

volts, a problem

or

8.

CKQ)

o

COM

terminals

14

volts,

and

on

the

the

charging

measure

using

the

alterna-

go

directly

next

page.

circuit;

the

a

iie@J~fI-~=110

ENGINE
GROUND

ALTERNATOR

A

WARNING:

hot.

Do

Use this troubleshooting section to determine

with

exists
determined that
have a qualified technician check

The alternator charging circuit

the

and
or a battery selector switch
to
along
starting
the service battery's charging circuit
tor.

Testing

service

isolate

with

battery

TROUBLESHOOTING

A failed

not

touch

until

the

charging circuit or

the

battery.

the

batteries

the

service

but not the service

the

Alternator

altemator

the

altemator

alternator or voltage regulator

charges

An isolator

is

usually mounted in the circuit

so

the starting battery

battery.

If

SEE
FOR
TO

can

has

with

the

it.

the

with a diode,

the

alternator

battery,

and

not with the alterna-

OPTIONAL

become

alternator.

starting battery

the problem

WIRING

DIAGRAM

WIRE

CONNECTIONS

ALTERNATORS

very

cooled

down.

if

a problem

If

is

faulty,

a solenoid

is

not discharged

is

charging

it

is

RED

is

the

in

..

3.

4.

5.

6.

TESTING
BATTERY/ALTERNATOR
(ENGINE

Tum
Ensure
connections

A

charging

switch

If

a

ensure that it
Tum
Check

tion,

THE

STARTING

RUNNING)

off the

engine.

that the battery terminals

are

CAUTION:

circuit,

when

battery

selector switch

on

the

ignition

the battery

the

reading should be

the

is

tight

To

never

engine

on

the

voltage.

Inspect

and

avoid

correct

switch,

clean

shut

is

is

If

12

all

wiring

and

..

damage

off

the

running!

in

the

charging

setting.

but

do

not

the

battery

to

13

and

connections.

the engine

to

the

battery

engine

start

is

in

volts.

ground

battery

circuit,

the

engine.

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

are

testing

often

with

mixed

disconnect a shore
converters,
DC

testing.

and
No

knowledge

the

engine

parts!

a multi

together

shut

AC

of

Keep

down

tests

AC

circuits.

make

away

meter:

in

power

the

should

certain

from

marine

cord,

engine

be

Engines &·Generators

24

TESTING

ALTERNATOR

(IGNITION

THE

VOLTAGE·

ON • ENGINE

OFF)

-=-

~

0..,...--MULTIMETER

coM

GROUND

7.

Now
minal
the
tor
neither
between
connections

check

(B+)

alternator

is

in

the

of

the

the

the

voltage

and

ground

will

be

circuit

the

above

alternator

- look

between

If

the

circuit

the

same

as

alternator

is

true, a problem
and

the

battery.

for

an

opening

DC

the

alternator

is

good,

the

battery,

voltage

will
exists
Check

in

the

charging

MULTIMETER.

ELECTRICAL

output

ter-

the

voltage

at

or if

an

isola-

be

zero.

If

in

the

circuit

all

the

circuit

(]Z5J

G

COM

SYSTEM

Checking

Check
have a voltage
running.
charging
circuit
isolator,

the

voltage

If

circuit.

by

checking

battery

the

Service

between

not,

there

Troubleshoot

switch,

of

the

service

13

is a problem

the

wiring

and

Battery

battery.

and

14

volts

in

the

service

and

connections,

the

battery

the

This

when

service

battery

itself.

battery

the

engine

battery

charging

the

should

is

solenoid,

TESTING
BATTERY/ALTERNATOR
(ENGINE

s.

Start

alternator output
The

voltage
should be between
is

over-

service

NOTE:

voltmeter
at

the

tery voltage at the B output

If

12

wiring and look for breaks

12

VOLT

The engine

on

shown
diagrams
electrical

A

CAUTION:

clrcultl
the

engine

however,

englnets

THE

STARTING

RUNNING)

the

engine

again.

and

reading for a properly operating alternator

or

under-charging,

facility.

Before

removing the alternator for

to

ensure

EKC

terminal if

volts

is

not present at

01;

CONTROL

has

a 12 volt DC electrical control circuit that is

the·

wiring

diagrams

when

troubleshooting or

system.

To

avoid

never

shut

off

Is

running.

to

avoid

electrical

electrical circuit.

BATTERY

The

minimum

the

engine's 12 volt

Cranking

recommended capacity of the

DC

Amps

(CCA).

-1..=o-c=::.--I

-

Check

the

voltage

ground.

13.5 and 14.5

that

12

the

volts.

If

have

it

repaired

volts DC excitation is present

previous test showed only bat-

terminal.

the

EXC

terminal,

and

poor connections.

CIRCUIT

that

follow.

Refer

when

servicing

damage
the
Shut

control circuit

engine

off

the

shorts

to

the

battery

engine

when

is

600 - 900

battery

switch

battery

working

ENGINE
GROUND

between

your alternator

repair,

battery

at

a reliable

trace

to

these

the

charging

while

on

Cold.

the

use

a

the

DC

swltch

the

used

in

,SERVICE

TESTING

BATTERY

A

CAUTION:

do

not

use a high

perfonnlng

Battery

Rev.iew
establish a systematic
engine's starting

D Monitor

D Check the electrolyte

l

D
D Make certain that
D

A

cause
protective

Care

the

engine

hydrometer.
Use

only

level.

tight

to

Keep

your

WARNING:

severe

To

avoid

voltage

tests

on

the

manufacturer's

maintenance

batteries

your

voltmeter

operation.

distilled

the

gear.

battery

batteries

Sulfuric

bums

water

battery

posts

on

damaging

tester

(i.e. a megger)

altemator

recommendations

schedule

and

house

batteries.

for

proper

level

and

specific

to

bring

cable

connections

(and

to

your

clean

and

free

acid

In

lead

skin

and

damage

electrolytes

BATTERY

THE

(ENGINE

the

altemator

charging

for

chargip,g

gravity

engine).

of

corrosion.

batteries

clothing.

SERVICE

RUNNING)

dlodes

when

circuit.

and

then

your

during

with

to a proper

are

clean

can

l

a .

and

Wear

Engines.& Generators

25

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat solenoid.

PREHEAT is pressed at the control panel this solenoid

When
should

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

INSPECTION

To

inspect the plug, remove the electrical terminal connec-

tions, then unscrew or unclamp each plug from the cylinder
head. Thoroughly clean each plug's tip and threads with a
soft brush and cleaning solution to remove all the carbon and
oil deposits. While cleaning, examine the tip for wear and
burn erosion;

if

it has eroded too much, replace the plug.

TESTING

An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and
the other
glow plug
method can be used with the plug in or
You.
(8

A

to
testing

to

the body

wiII

can also use an ammeter to test the power drain

to 9 amps per plug).

WARNING:

the

touch.

the

plugs

of

the glow plug, as shown. A good

have a 1.0- to 1.5-ohm resistance. This

out

of

the engine.

These

glow

plugs

will

become

Be

careful

not

to

burn

your

fingers

very

hot

when

Re-instaII the plugs
plugs should get very hot (at the terminal end) within

25 seconds.
short circuit. When reinstalling the glow plugs, use anti-seize
compound

Glow

A

than

Qn

Plug

Tightening

WARNING:

30

seconds

in

If

the plugs

the threads.

Torque

Do

Tightening

(1.0

the engine and test them again. The

don't

heat up quickly, check for a

7 -11Ib-fl

not

keep a glow

TERMINAL

(1.0

END

-1.5

plug

kg-m)

on

for

more

torque:

-1.5

m-kg

(7

-

llft-lb)

GLOW

PLUG

THE

OHMMETER

TEST

20 to

TIP

Engines & Generators

26

WIRING

SCHEMATIC

12

vee

+

~

,

..

~

C.B.

=

II

BAT

KEY

SW.

IGN

START

SOL.

r-,

I I
I I

....

_

...

PREHEAT

r--,SOL.

I

C.B.

L.._.J

o

I

ALARM

+

~

(

~,'OA

.:

~

.;

~

STARTER

M

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

GlOWPLUGS

ALTERNATOR

~

L

1FT

PUMP

P

F'UEL.

IWHEH

SOl'e-USEDI

-

--

s~N~iR

~

".T.

'XJ

SENDER

0..

\!J

W.

T.

SWITCH

GNO

GNO

w.

T.

GAUGE

GND

l~

1

TACHOMETER

VOL.

+

S

TMETER

-

------,

I

I

I

I

I

I

I

I

I

.............. J ..

,

TO

At

T.

:

'"'"TJt

l'

~

,

.....

Il2c

ADMIRAL
PANEL

L.~~w~CuimFTl::::==:-:---,

'H'oi:'D

298

NOTES:

I.

THIS

PRODUCT

STARTER.

~~~r N~O:~t

2.

AN

ON-Orr

~:

f~O~N~~~T

SWITCH

3.

THE

PINK

.c.

THE

GRAY

••

IS

PROTECTED

EXCESSIVE

I

~~~Af~~5D~g

SWITCH SHOULD

T~~O~~Tn~1

SHOULD

NOT

WIRE

AT

WIRE

AT

PRESTOLITE\LEECE-NEYILLE

SY A MANUAL

CURRENT

WILL

CAUSE

1~:~~:N~U~bN~~C'U:~T~~~~

BE

IHSTALlED

N~ N O~N I i~E:~~~~Y

BE

USED

TO

MAI'IE
UNUSED
UNUSED

8RN

OR
AND
AND

PLUG 2 IS

PLUG

Z IS

ALT

'14

RESET

CIRCUIT

THE

SREAKER

TO

BETWEEN

BREAK

H~c

THE

BATTER"

~~D I ;H~~C

L~~~~ N;E~~~

THE

CIRCUIT.

SHOULD

8E

INSULATED, CAPTAIN

SHOULD

BE

INSULATED.

NOTE;
WIRE

FOR

TO

BE

BREAKER

LOCAHD

NEAR

TRIP

AND

~=f~:~Ng~~

AND

STARTER

~~~i'

ADMIRAL

BATTERY

UPGRADED

TO

THE

THE

ENGINE

W~:~:i

TO

F

UN~T

f~~ ~CH

PANEL

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PANEL

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AN

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10

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THIS SIDE

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TEST

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SCHEMATIC

#39144

PANEL

I I 0

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MALE

ON

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CONNECTOR

THIS SIDE

100

WHT

AMP.

ALT.

CD

RED

#14

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.14

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51

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ALTERNATORS
8ZB:IV

IOEVI

OPTIONAL ALTERNATORS®

13:'.iA.

®

&.

lOst::

VI

Engines & Generators

27

1"6'

SEE

NOTE

21

I~

1

+A£l

~~

aAI..I.E.B.l

NOTE:

An

should

be
circuit.to
starter

from

an

emergency

leaving

the.bdat.

volt

engine

typically

draw

amps

when

switch

with a continuous
rating

of

175

VDC

will

normally

this

function,

must

never

"make"

the

r----

1

.J

1
1
1

on-off

switch

installed

in

disconnect

the

battery

and

when

Twelve

starters

200

to

cranking.

amps

at

serve

but a switch'

be

used

to

starter

circuit.

this·

the

300

A

12

in,

WIRING

.10

"

SI

PI

R D

DIAGRAM,

'1<

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114

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PANEL

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11

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.

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- - - - - - - - -

WIRING

DIAGRAM

#39144

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.18

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.18

BlK

Engines & Generators

CAPTAIN

PANEL

TACHOMETER

28

DESCRIPTION

TIle

starting

system

and

starter

button.

When

the

starter

button

current

flows

and
energized
into
to
serves
flywheel.

To

pnuon

is
engine

motor

Once

ping
contact
flow

.

magnetic
plunger
from

the

coil,

reach

to

prevent

gear

splnled

may

itself

the

the

with

of

electricity

is

its

coil

becomes

and

closes a set

the

starter

push

that

damage

incorporates

to

the

starter

speed

started

button

activation

the

battery-to-start

fields

and

released,

engagement

includes

on

energizes

an

motor.

At

starter

pinion

to

the

starter

an

armature

the

rotation

is

of

the

solenoid.

is

interrupted

the

starter

its

movement

with

the

battery,

the

instrument

the

starter's

electromagnet,

of

contacts

the

same

time,

to

mesh

motor

when

over-running

shaft.

The

of

the

'pinion

released,

the

the

TIle
cables
to

the

ceases

also

engine

current

plunger

by

starter.

its

pulls

flywheel.

starter

motor,

panel

solenoid

which

which

allow

the

with

the

the

(one-way)

rotation

but

not

flow

is

a

coil

This

rotation.

the

starter

STARTER

solenoid,

is

depressed,

coil.

The

pulls

the

plunger

high

current

plunger

spring,

teeth

engine

clutch

of

the

the

starter

ceases,

pulled

weakens

As

the

drive

also

on

the

starts,

which

running

stop-

out

of

and

the
the

solenoid

gear

the

MOTOR

IGNITION

TERMINAL

TO

CONTROL

PANEL

To

test

the

ignition

circuit,

locate

of

the

small

tem1inaJ
Use a screwdriver,
ignition

teID1inaI

the

solenoid.

Iftbe starter cranks, the fault

solenoid

If tbe
motor

is

probably

don't

to

the

clicks

faulty.

studs

and

touch

positive

but nothing

~~--"""\(M)

In

the

is

wired

the

blade,

battery

lies

else

ignition(s)

connection

with

to

the

ignition

to

jump

the

ignition

happens,

terminal

from

the

TERMINAL

(it

circuit).

that

teIDlinal

circuit

starter

is

on

one

MOTOR

---t':~-+-

TYPICAL

STARTER

MOTOR

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

and

that

the

starting

system

wiring

clean

and

tight.

Pay

particular

connections
To

check
never
the

wires

resistance.
Using a l11Ultinleter,

stud

If

you

more

on

read

the

and

the

on

the

wiring,

than

tenninals

Repair

start

12

volts,

engine

try

10

seconds

or

replace

test

solenoid

tbe starter

attention

block.

cranking

at a tinle,

looking

any

the

voltage

and

the

slups

batteries

connections

to

the

starter

then

for

warm

trouble

between

engine

is

faulty.

the

for a few

run

spots

spots.

the

block

are

at

full

(termiI1als)

ground

wiI'e

seconds,

your

hand

that

indicate

positive

(ground).

charge

are

along

terminal

IGNITION

TERMINAL

TO

CONTROL

PANEL

If nothing at

Check

the

battery

connections.

A

WARNING:

fly

when

jumping

space

is

free

gasoline.

all

happens the

isolation

It

is

also

of

potentially

solenoid

switch

possible

There

that

will

terminals.

isn't

and

inspect

the

solenoid

be

arching

Be

certain

explosive

~

getting

the

wiring

is

defective.

and

sparks

the

engine

fumes,

-(+)

POSITIVE

TERMINAL

current·

will

especially

/"""WESTERBEKE

I EnQines & Generators

29

STARTER

MOTOR

SERVICE

Westerbeke
serviced

Ifreplacing

~---.-

(+)

POSITIVE

TERMINAL

certified
standards.

~...,....---(M)

..

r':'~~

~i~OL(:jfJ""~__,

TERMINAL

TO

1.

Disconnect

2.

If

starter

3.

Test

again

by
screwdriver
screwdriver
would

cause a short.

jumping

blade

firnlly

blade

to

the

between

touch

two

the

large

terminal

the

studs.

solenoid

or

studs.

Do

starter

Hold

not

allow

casing,

the

the

this

Label
wires

4.

Remove

5.

Remove
will

A

WARNING:

starting

current

There

should

will
be

be

arching

flowing

thru

as

the

the

full

blade

of

the

screwdriver.

uses a standard

or

rebuilt

the

starter

for

marine

If

in

doubt,

REMOVE

FOR

the

necessary,

remove

motor.

and

disconnect

to

touch,

the

starter

the

starter

have

to

be

at

any

starter

motor,

use.

Automotive

contact

SERVICE

negative

tape

turned

battery

any

the

over
mounting
from

to a different

marine

starter

motor

automotive

make

certain

starters

your

WESTERBEKE

cable.

components

wiring

from

the

tenninals).

bolts.

the

engine.

motor

the

to

the

In

some

angle

new

do

not

gain

starter.

to

which

full

cases

clear

can

be

service

center.

motor

is

meet

USCG

dealer.

access

to

(Do

not

the

starter

obstructions.

the

allow

If

the starter

If

the starter

If

no

NOTE:

the

pre-engaged
engages
screwdriver
motor

provide

magnetic
the

solenoid

spins,
fails

arching occurred. There

Starter

motors

model,

the

starter
to

bypass

without

engaging

the

power

field

for

are

bad.

the

to

motor

to

the

the

solenoid

spin,

are

either

the

to

the

solenoid

the

solenoid.

ann

to

is

faulty.

the motor

is

po

inertia

solenoid

the

flywheel

on

flywheel.

HopefUlly

mave

even

is

probably

juice reaching the

type

also

maves

of

such

Tum

the

though

faulty.

or

pre-engaged.

.an

the

engine.

a

starter

starter

it

will

create

the

ann

will

switch

contacts

solenoid.

In

that

Using

a

run

the

on

enough

inside

to

Engines

30

& Generators

DUAL

OUTPUT

DESCRIPTION

Dual output and high output alternators are available
optional equipment on most WESTERBEKE engines. These
alternators
add-on equipment at anytime.

Dual alternators can be configured to charge two banks
batteries
charge each set

can

be installed during factory assembly or

at

the

same time

of

or,

using a battery selector switch,

batteries separately.

as

as

of

TO

INSTALLATION

If

an

optional dual alternator has already been factory installed, .
simply follow the WESTERBEKE wiring diagram and the
engine installation instructions.

If

the new dual alternator is being added
the-boat"
instructions below:

1.

2. Remove the alternator and disconnect or tape off the

3. Install the new alternator.

4.

engine, carefully follow the alternator installation

Disconnect the alternators negative cable from the
battery.

output [positive] cable.

Attach a new heavy gauge output cable[s] from the
alternator's output terminal [s]. Using the cable sizes
indicated.

LENGTH

_REQUIRED

[ALWAYS

USE

FINE

Up

TO

STRAND

Do

not reuse.

20'

CABLE]

#0

to

an existing "in-

WIRE

ALTERNATORS

SPACER
BRACKET

DUAL

OUTPUT

[CHARGING

ONE

TO

MOUNTING

ALTERNATOR

BATTERY]

S.

Make certain that the batteries negative post ground
cable to the engine block is the same heavy gauge as

the positive cable.

6. Mount the regulator
location.

a. Connect the black wire to the ground terminal on the

alternator.

A

CAUTION:

out

first

grounding

b.

Plug the 2-pin connector into the alternator, make

certain it

c. The red

the batteries positive

d.

The brown wire "keyed ignition"
which actuates the regulator, this wire must connect
to a switched

is

"battery sense" wire should be connected to

WESTERBEKE

connection.

Dual

Pulleys

A variety of accessory pulleys for high powered and dual
charging alternators are available from your
dealer.

to

a flat surface in a cool dry

Do

not

connect

the

regulator.

firmly seated.

[+] post [or the positive cable].

[+]

12 volt source. Refer to the

WIRING

any

DIAGRAM for the proper

power

source

is

the key circuit

with-

TO

~:;::;--

"BATIERY

TO

yCONNECTS

DUAL
[CHARGING

SENSE"

BATTERY

BLUE

LEADS.
CONNECTS

ALARM

BUZZER.

WIRE

CONNECTS

OIL

PRESSURE

OUTPUT

POSITIVE

POST

TO

PINK

AND

THE

PINK

TO

THE

THE

BLUE

TO

TNE

SWITeN.

ALTERNATOR

TWO

BATTERIES]

Engines & Generators

31

DUAL

OUTPUT

ALTERNATORS

TROUBLESHOOTING

NOTE:

Before

troubleshooting,

belts

are

tight and

Regulator

the

Testing

batteries

The red "battery sensing" wire A connects
must always read battery voltage. If battery voltage
present, trace the wire for a bad connection.

The orange wire S should read 0 volts with the
volts [approximately] with the
incorrect, trace the wire for a bad connection.

The blue wire F supplies current
voltaO"e

will

vary

depending
loadl;'m. The readings can
key

on,

0 volts with the

KEY

ON -NO

VOLTAGE

KEY

OFF -BATTERY

REGULATOR

Terminal/Color

I
A

S
F
Alt.

TEST

Brown
Red
Orange
Blue

Output

POINTS

Ignition

o

12.6

o
o

12.6

REGULATOR

VOLTAGE

AND
Off

volts

volts
volts
volts

volts

make

certain that

are

in

good

key

on.

If

the readings are

to

the alternator fields, its

on

the battery charge or actual

vary

from 4 to

key

off.

IS

DEFECTIVE

REGULATOR

PROPER

Ignition

2

-12

12

o

volts
10-11
12

VOLTAGE

On

volts

volts

volts

volts

IS

DEFECTIVE

Engine

14.2

14.2

4 -

14.2

the

condition.

to

the battery, it

key

12

volts with the

Running
volts
volts

6 - 8

volts

12

volts

volts

drive

is

off,

not

12

Alternator

The regulator

Testing

is

functioning properly

are in good condition.

1.

Test

the voltage

off-key

on.
the voltage
should read the

2.

Hold a screw driver close [1/2"]
If voltage
not,

the problem

[open

circuit].

3.

Start the engine,
indicate

indicate

14.2

the

Apply a load

should maintain

The

in

the

same.

is

present

volts

alternator

such

at

the

voltage

plug

you

may

be

at

fast idle the output terminals

[no

is

as

an

at

least

indicates the alternator

NOTES:

When

the

engine

is

first

started,

the

alternator

change
There

is

normal.

When

become

will

the

in

the

sound

be

a slight

alternator

quite

hot.

to

"kick in" andtake.the

of

the

wine

is

producing

alternator plug

at

the

alternator

[blue

wire

F]

to

the alternator

should

feel

the brushes

load].

A reading of

not

performing

electJ.ic

13.8

is

engine

from

volts.

faulty.

it

the

bilge

13

takes
will

occur.

alternator

high

and

the batteries

with

the

terminal F and

from

the

the magnetic

[worn]

or

12.6

properly.

pump,

the

volts

or

a few

moments

load.

A noticeable

when

amperage,

engine

regulator

puJley.

field.

the

rotor

should

would

voltage

less

for

the

it

can

If

load

When

and

replacing

replace

dual

the

belts

alternator drive

in

matched

belts,

pairs.

always

purchase

Engines & Generators

32

The

following
relating
lems,

troubleshooting

to

engine

and

the

recommendations

service,

the

table

describes

probable

to

overcome

ENGINE

certain

causes

of

these

TROUBLESHOOTING

problems

these

prob-

problems.

NOTE:

ampere

the

back

the

same

The

engine's

manual

of

bracket.

the

electrical

reset

engine.

circuit

The

system

breaker

preheat

is

protected

located

solenoid

by

a

20
on. a bracket
is

mounted

at

on

No

panel

indications;

or

fuel

pump

is

on

and

PREHEAT

START

button

engagement.

START

button

indications

fuel

Engine
start,

Engine

Battery

Battery

OK;

solenoid

cranks,

fuel

solenoid

can't

runs

not

charging

not

be

down.

Problem

fuel

is

not

working

button

is

depressed,

is

depressed;

starter

solenoid

functioning.

but

does

energized.

stopped.

solenoid

(key

is

depressed).

no

panel

not

switch

starter

OK;

Probable

1.

Battery

2.

20-amp

3. 1 O-amp
preheat

4.

Loose

battery

5.

Preheat

1.

Connection

2.

Gear

shift

3.

Faulty

switch.

4.

Faulty

solenoid.

5.

Loose

battery

6.

Low

battery.

1.

Poor

connections

2.

Defective

1.

Faulty

fueling

2.

Preheat

3.

Low

battery

1.

Faulty

DC

Disconnect

2.

3.

Fuel

run

1.

Oil

pressu

2.

High

resistance

3.

Low

resistance

4.

Poor

battery

5.

DC

altemator

(tachometer
DC

charge

1.

2.

Altemator

switch

not

Circuit

breaker

breaker

solenoid

connections.

solenoid

to

solenoid

not

in

connections.

fuel

solenoid.

system.

solenoid

power.

altemator.

fuel

shut-off

solenoid

re

switch.

leak.

connections.

not

not

circuit

drive.

Cause

on.

tripped.

tripped

on

not

operating.

faulty.

neutral.

to

fuel

solenoid.

faulty.

cable.

will

not

de-energize.

leak

to

ground.

cHarging

operating).

faulty.

1.

Check

2.

Reset
circuit

3.

Check
preheat

4.

Check
engine

5.

Check

1.

Check

2.

Gear

HURTH

3.

Check

4.

Check

5.

Check

6.

Check

1.

Check

2.

Check

fuel

1.

Check

1

a.

Check

1b.

Fuel
fuel

2.

Check

3.

Switch

3a.

Replace
Remove

1.

2.

Check

offthe

3.

Manually
solenoid

1.

Observe
is

Check

2.

lines.

after

3.

Check

Check

4.

corrosion

5.

Check

DC

1.

Perform

Testing

2.

Check
for
volts

not

VerificationJRemedy

switch

and/or

battery

breaker;

if

and
the

(+)

solenoid
connection.

shift

switch
that

battery
battery

connections.
that

run

that
for

filters

system.

solenoid.

connection

fuel

running.

wiring.

(Do

short

all
cable

connections,

ELECTRICAL

drive

loose

are

breaker

check

circuit

voltage

solenoid.

ground

HSW

solenoid.

to

batteries.

the

both

connection

must

12

12

fuel

air

clogged.

combine

Exc.

disconnect

at

the

if

gauges

not

is

wires

DC

Battery

connections.
present

to

stud.

Check

"S"

terminal

be

in

neutral

TRANSMISSIONS).

with

ohmmeter.

volts

are
connections.
charge

state.

volts

are

valves

are

in

fuel

system.

Replace

house

connection

at

shut-off

the

injection

and

Test

the
Insert

sensitive

start

engine.)

located.

for

temperature

connections

check

SYSTEM/ALTERNATOR.

voltage

check

Charging

belt

tenSion;

at

the

connections.

trips

for

shorts

at

and

starter

battery

for

(see

present

present

open.

Bleed
fiHers

and

at

alternator;

lever.

12

volt

pump.

panel

lights

oil

pressure

Remove

at

battery

belt

of

generator

Circuit.

altemator

Check

output

Exc.

terminal.

again,

check

to

ground.

after

the

solenoid

cable

voltage.

NEUTRAL

at

the

solenoid

at

the

(+)

air

from

and

start

batteries.

repair

Pull

connection

are

activated

switc~.

(0 -.25

amp)

connections

rise

to

locate

for

loose

tension,

should

with

preheat

breaker

on

the

and

(-)

connection

connections.

SWITCH

connection.

connection

fuel

system.

bleed

air

from

alternator.

lever

back

to

to

the

fuel

when

meter

in

and

the

fault.

connections,

test

altemator.

charging

circuit.

tum

freely.

voltmeter.

solenoid

under

on

the

close

run

engine

battery

replace

See

See

Check

Ensure

12

to

(continued)

Engines & Generators

33

ENGINE

TROUBLESHOOTING

Engine

slows

Engine

overheats/shuts

Engine

alarm

Engine

alarm

Exhaust

smoke

Problem

and

stops.

sound

pulsates.

sounds

continuously.

problems

down.

1.

Fuel

2.

Switches
or

disconnected.

3.

Fuel

4.

20

Amp

5.

Exhaust

6.

Water

7.

Air

intake

1.

Raw

2.

Coolant

1.

Loss

Oil

pressure

2.

1.

Engine

2.

High

too

1.

Blue

2.

White

3.

Black

Probable

lift

pump

failure.

and/or

starvation.

circuit

breaker

system

in

fuel.

obstruction.

water

not

circulating.

not

circulating.

of

oil.

switch.

coolant.

temperature

Iowa

temperature.

smoke.

smoke.

smoke.

Cause

wiring

loose

tripping.

is

restricted.

switch

opens

at

Verificalion/Remedy

1.

Fuel

lift

pump

should

pump

with

spare.

2.

Inspect

wiring

Inspect

switches

3.

Check

fuel

supply,

4.

Check

for
Ensure
cause

5.

Check
exhaust

6.

Pump

bleed

7.

Check

1.

Raw

2.

Obstruction

2a.

Thermostat -remove
Replace

2b.

Loss
for

2c.

Broken

2d.

Air
bleed

1.

Check
oil

2.

Replace

1.

Check

.

2.

Check
check

1.

Incorrect

1a.

Crankcase
through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel
insufficient
exhaust

3b.

Improperly

3c.

Lack

ventilation.

3d.

Overload.

high

breaker

tripping.

for

blockage,

elbow.

water

fuel

system.

air

intake

water

pump

thermostat

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add

dipstick,

drain

hose

oil

pressure
engine
for

satisfactory

with

ohmmeter,

grade

is

the

is

running

injector

grade

bum

incomplete

air

system;

timed

of

air -check

make a distinct

for

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

from

fuel

tank(s);

filter

cartridge.

failure.

Check

at

raw

water

intake

and

test

hoses,

belts -tighten/replace.

run

engine

coolant

as

needed.

look

for

oil

switch.

level.

operation

replace

engine

oil.

with

cold.

incorrect

fuel.

due

to

proper

combustion

air

injectors

air

intake

leaks

injector

intake).

or

connection.

coolant

of

overfilled

exhaust).

or

of

for

check

ticking

and

loose

operation.

fuel

draw

sensitive

hose,

change

impeller -replace.
or
in

and

at

with

if

faulty.

engine

high

vaives,

and

connections.

lift

pump.

during

operation.

to

heat

carbon

filters

raw

water

hot

water.

hose

clamps,

open

the

oil

filter

and

switch

oil

(oil

is

timing.

back-pressure

(check

or

poor

air

filter.

Check

sound.

Replace

which

would

buildup

at

and

filter.

drain

plug,

pressure

cap

to

at

bypassed,

blowing

out

in

exhaust

for

restrictions

compression.

for

proper

etc.

or

in

TROUBLESHOOTING

If

the gauge reading is other than what is normally indicated
by the gauge when the instrument panel is energized, the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition

(B-)

and the Negative

terminals
Assuming that there is 12 volts as required, leave the probably defective and should
instrument panel energized and perform the following steps: Assuming the gauge is

1. Disconnect the sender wire at the gauge and see

gauge reads zero, which is the normal reading for this Check that the engine block is connected to the ground.
situation. Some starters have isolated ground terminals and

2. Remove the wire attached to the sender terminal at the battery is connected to the starter (both plus and minus

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

of

the gauge.

COOLANT

TEMPERATURE

If

both

AND

of

the above gauge tests are positive, the gauge

OIL

PRESSURE

GAUGES

(B+) conductor from the sender to the gauge or with the sender.

If

either

of

the above gauge tests are negative, the gauge is

be

replaced.

OK, check the conductor from the

if

the sender to the sender terminal at the gauge for continuity.

if

the

if

the gauge reads terminals), the ground side will not necessarily be connected

~

WESTERBEKE

Engines & Generators

34

is

NOTE:

WESTERBEKE

ments

be
is

below

ENGINE

performed

provided

to

by

assist

ADJUSTMENTS

recommends
a competent

the

that

engine

mechanic.

the

following engine adjust-

mechanic.

The

information

DRIVE

Proper inspection, service and maintenance of the drive belts
is

Drive Belts under MAINTENANCE

Drive belts must
will
ally damage the alternator. Drive belts that are too tight
pull the alternator out of alignment and/or cause the alterna­tor
also cause rapid wear
of the coolant pump's bearing. A slack belt or the presence of
oil
operating temperatures and tachometer variations.

The drive belt

no

(12mm)

midpoint between the

belt.

Adjusting

1.

2.

3. Pivot the alternator

4.

5.

BELT

ADJUSTMENT

important for the efficient operation of your engine

SCHEDULE).

be

properly tensioned. Loose drive belts

not provide proper alternator charging and

to

wear out prematurely. Excessive drive belt tension

of

the belt

on

the

belt can cause belt slipping, resulting in high

is

properly adjusted if the belt can be deflected

less

than

3/8

inch (lOmm)

as

the belt

A spare belt or belts should always

A

WARNING:

drive

belt's

Loosen the alternator adjusting strap bolt and the base

mounting bolt.

With

the

edges.

or right
Tighten

bolt.
Run

the engine for about 5 minutes, then shut

recheck

Never

tension

Belt

Tension

belt

loose,

as

required,

the

base

the

belt tensions.

is

depressed with the thumb at

two

while

inspect

on

to

mounting

and

reduce the service life

and

no

more than

pulleys

attempt

on

the longest span of the

to

cbeck

the

engine

is

for

wear,

cracks

the base mounting bolt
loosen or tighten.

bolt

and

the

be

carried

or

in

operation.

and

adjusting

will

112

the

on

adjust

frayed

to

down

(see

eventu-

will

can

inch

board.

the

the

left

strap

and

FUEL

INJECTORS

In

case of severe vibrations and detonation noise, have
injectors checked and overhauled by
injection service
loss of positive fuel pressure
in

injector
clean room environment, it
injector

Before removing the old injector, clean the area around
base
falling down into the injector hole.
out easily and
the injector side-to-side with the aid of the socket
free

The injector seats in the cylinder head
washer.
replaced with a
installed.

INJECTOR

43-51

as

of

the injector

it, and then lift

This washer should be removed with the injector

TO

fI-lb

(6.0-7.0

center.

Poor fuel

to

faults.

Since fuel injectors must

is

a spare should a problem

to

help prevent any rust or debris

is

held in by carbon build-up or the like, work

it

out.

new

washer when the

CYLINDER

FUEL

HEAD

TIGHTENING

mka)

INJECTOR

an

quality,

the injection

best

to

carry at least

occur.

If

the injector

on

new

TORQUE

authorized fuel

contaminants

pump

can

be

serviced in a

one

from

will

wrench

a copper sealing

injector

is

the

and

result

extra

the

not

lift

to

and

RAW

WATER

The tension of the
releasing

forth.

and
checked often.

STARTER

Refer

to
included in this manual are basic troubleshooting
procedures for both the starter motor and the alternator.
also that there

repair and rebuilding of starter motors and alternators.

PUMP

the

pumps fasteners and sliding the pump back

The water pump belt should

AND

the engine troubleshooting chart

are

BELT

raw

water pump belt

ALTERNATOR

automotive shops that specialize in the

SERVICE

is

adjusted

be

firmly

in

this

by

tight

and

manual.

and

test

Also

Note

Engines & Generators

35

VALVE

1.

2.

3.

NOTE:

CLEARANCE

Wann

the

engine to nonnal operating temperature.

Pull off the air breather pipe
Remove

cover
Remove

enable
position
Valves
adjusted at

the

to

expose

the

the

each

are

Retorque

rocker cover bolts

the

glow

plugs

crankshaft

cylinder

adjusted

TOC

of

the

cylinder head bolts

engine s valves.

4.

Loosen

the

head

bolts

NOTE:

WESTERBEKE

be

ments
below

performed by a competent

is

provided

ADJUSTMENT

from

the

rocker

and

remove

rocker shaft

from

to

be easily rotated

for

with

its

compression

in

and

valve

valve

the

each of

piston

the

adjustment.

in

the

stroke.

before

the

reverse order of tightening.

ENGINE

ADJUSTMENTS

recommends

to

assist

the

cover.

the

rocker

assembly.

cylinders

by

hand

to

to

cylinder being

adjusting

the

that

engine

mechanic.

8.

the

following engine adjust-

mechanic.

The

information

Adjust each valve's clearance
(0.03mm)
valve
engine

feeler gauge between

stem.

Make

sure

is

cold.

to

adjust

by

inserting a 0.012in

the

rocker ann

all

valves

when

and

the

the

13

5.

Tighten

6.

85

Set
and

If

the

90

ft

-Ib

the

piston of No.1 cylinder

check

the

clearance
Intake - No.1
Exhaust -

7.

Turn

the

crankshaft

cylinder at

following specifications:

Intake - No.3
Exhaust - No.2

WHEN

NO.4

I

41NTAKE

4

EXHAUST

WHEN

NO. 1 CYLINDER

9 5

head

bolts

(11.8

-12.5

the

valve

is

and

No. 1 and

TOC

(compression)

and

and

CYLINDER

31NTAKE

f

EXHAUST

1

4

in

the

order

m-kg)

clearance at

incorrect, adjust

No.2 cylinders;

No.3 cylinders.

once,

setting

No.4 cylinders;

No.4 cylinders.

IS

AT

TOP

DEAD

EXHAUST

2

2

INTAKE

I

IS

AT

TOP

DEAD

8

shown.

to

TOC

(compression)

each

position indicated.

to

specifications:

and

the

piston of

and

adjust

and

CENTER

NTAKE1

~

EXHfUST

CENTER

9.

Install

HEAD

ENGINE

12

Torque

to

at

No.

4

the

I"!!""'!.""!""!""~

Check

the
engine,
the

fuel
adapter
compression tester
the

starter motor until
Repeat

this
dramatically (at least
average of
by

more

COMPRESSION

GAUGE

COMPRESSION
COMPRESSION
LIMIT

BETWEEN

If

a

weak

is

either valve or piston related. Check

for

the

weak

If

the

cylinder

the

cylinder

If

compression

the

cylinder head

COVER

BOLT

TORQUE

cover.

2 -3

ft

-Ib

(0.3 -0.45

COMPRESSION

compression pressure.

remove
in

all

fuel

shut-off solenoid

the

injector hole or

on

the

injectors, or

wire,

the

process for each

20%)

the

others. Compression pressure should

than

42.7

psi

(3.0

To

and

install a compression

glow

plug
adapter
pressure

and

reaches a maximum

cylinder.

lower compression

2

)

kglcm

at

I

~

PRESSURE
PRESSURE

CYLINDERS

cylinder

cylinder,

to

is

is

still

seal

comes

STANDARD
LIMIT

flanked

adjust

low,

apply a small

the

rings

up -the

by
as

and

rings

427
384

42.7

healthy

needed

repeat

m-kg)

do

this,

wann

the

glow

plugs, disconnect

hole.

Connect a

crank

the

engine

Look for cylinders

than

200

rpm.

PSI

al200

RPM

(30.0

PSI

al200

RPM

(27.0

PSI

(3.0

Kg/em')

the

and

the

are

cylinder,

amount
faulty.

valve

test
test.

the

clearances

again.

of

with

value.

the

not

differ

Kg/em')
Kg/em')

problem

oil

into

with

Engines & Generators

36

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust­ments be performed
below is provided to assist the mechanic.

ADJUSTMENTS

by

a competent engine mechanic.

The

information

ENGINE

The
boat
propeller
the

The
however,

It

it

SETTING

To
locknut of
clockwise
reduce.

locknut.

engine

is

idle

normal

should

causes

adjust

IDLING

operating

size,

speed.

simply

be

chugging

THE

the

the

to

Once

SPEED

idling

speed

in

the

shaft

length,

idle

speed

put

quiet

and

and

IDLING

engine idle

idle

adjustment

increase idle

the

speed

is

pre-set

water

and

for

this

the

idle speed

smooth,

transmission

SPEED

speed

speed

is

set

,

at

the

other

variables

the

transmission

engine

is

should

not

racing

rattle.

(engine

bolt

and

and

counterclockwise

to

your

satisfaction,

THROTTLE

factory

such

650-950

feel

but

not

running),

turn

the

STOP

BOLT

but

once

the

as

can

affect

RPM,

comfortable.

so

low

that

loosen

the

bolt

to

tighten

the

(FACTORY

SET)

INJECTION

For

disassembly,
adjustments
pump
authorized
equipment.

ENGINE

This

solenoid

pump

be

taken

STOP

and

PUMP

inspection,

of

the

injection

to a qualified

to

service

SOLENOID

is

installed

is

activated

SERVICE

reassembly

pump,

injection

Diesel

KiKi

on

the

top

by

12

VDC

Troubleshooting

1.

The solenoid does not operate when
the keyswitch

a.

Are

the

h.

Is

the

c.

Is

12

connection?

2.

The solenoid does

the keyswitch is switched

a.

Check
at

the

key

off.

h.

Remove
pump

in

the

is turned "ON".

engine batteries

20

amp

circuit breaker

VDC

present

to

see

if

12

solenoid

and
solenoid

electrical lead

solenoid

ensure plunger

are

turned

at

the

solenoid

not

stop the engine when

"OFF'.

VDC

is

from

injection

and

not

sticking.

and

it

is

recommended

service

or

Zexel

injection

rear of

electrical

"ON"?

set?

still present

with

the

spring

internal

shop

the

injection

current.

the

J:=

SPRING

PLUNGER

FUEL

INJECTION

PUMP

(TOP)

Engines & Generators

37

TESTING

The

oil
oil
oil

engine.

continuous
pressure,
and
its

specified

To
install a
warming
2600

OIL

lubricating

pump.

The

pump,

which

filter,

oil

The

the

returns

test

the

oil

mechanical

up

rpm

and

cycle.

to

PRESSURE

system

is

engine

oil

drives

the

cooler

and

various

oil

then

returns

When

the

oil

pushes

open

the

oil

sump,

range.

pressure,

the

read

oil

engine,

the

remove
pressure

set

oil pressure

NOTE:

ments
below

a pressure

is

drawn

oil,

under
lubricating

to

the

oil

pressure

the relief

keeping

the

gauge

the

engine

ENGINE

WESTERBEKE

be

performed

is

provided

feeding

from

oil

the

oil

gauge.

system

the

oil

pressure,

points

sump

to

exceeds

valve

oil

pressure

pressure

in

it's

speed

in

at

by a competent

to

assist

using

sump

by

through

in

the

repeat

the

the

specified

the

oil

within

sender,

place.

After

approx.

ADJUSTMENTS

recommends

the

an

the

the

pump

then

that

engine

mechanic.

LOW

The

+

cates a worn
pressure

chart.

OIL

Occasionally a faulty
reading.
the
the

OIL

9 -13

the

following

mechanic.

OIL

PRESSURE

specified

0.1

kglcm

2

).

safe

A

bearings.

readings,

PRESSURE

When
threaded
sender.

PRESSURE

fHb

(1.2

-1.8

ends

SENDER

engine

adjust-

The

information

minimum

gradual

see

loss

For

the

ENGINE

oil

pressure

of

oil

additional

pressure

TROUBLESHOOTING

SWITCH/SENDER

oil

pressure

installing a

being

careful

AND

SWITCH

m-Kg).

OIL

PRESSURE

SWITCH

new

sender
sender,
not

to

TORQUE

is

4.3 + 1.4
usually

information

will

give a false

apply

teflon

close

off

the

psi

indi-

on

low

sealant

oil

(0.3

hole

oil

to
in

OIL

PRESSURE

WITH

ADAPTER

THIS

MECHANICAL
INSTALLED
THE
OIL

WHERE

ENGINE

PRESSURE

GAUGE

BLOCK

SENDER

TEST

THE

OR

IN

GAUGE

OIL

HOSE

PLACE

CAN

BE

ENTERS

OF

THE

INJECTION

PUMP

CONNECTION
ENGINE

OIL

GALLERY

TO

BLOCK

Engines

38

&.

Generators

DESCRIPTION

The information
Transmissions, the

SECTION

CONNECTION

HBW

recommend a flexible
mission
flexibly
deflections.
ing

the

SPECIFICATIONS

shaft

care should be

using a
manufacturers instructions.

Even
coupling or

bo~

boats
flange

gearbox

mounted,

is

not

transmission

should

universal

with

bearings

or

where

and

below

is

TRANSMISSION

applies

required,

the

to

all

models.

OF

GEAR

and

the

in

order to

The

installation of a

since

bearing,

is

not

be

protected

taken

to

prevent

joint

shaft,

engine

solidly

,*PRIVESAVER"

caused

by

hull

the distance between

stem

gland

is

less

HURTH

specific

propeller shaft if the engine

the

provided

exceeded.

from

to

the

TROUBLESHOOTING

BOX

WITH

connection

compensate

special

propeller thrust bear-

propeller thrust

the

value

However,

additional

torsional

make

certain

mounted,

will

distortions,

than

the

reduce

especially

transmission

about

HBW

PROPELLER

between

vibration.

32

the trans-

for

angular

will

be

specified

the

output

loads.

Special

to

observe

use

of a

stress

in

the

in

output

in

(812

HURTHHBW

TRANSMISSIONS

NOTE:

When

installing

is

taken

under

When

the

flexible

gear-

wooden

mm).

by

shifting
Bowden
sheaves,
support
threaded
gear

CONTROL

The
Upon
be
elements
actuating lever

plate:

be'O.5mm.
The

actuating lever
tion
coincide

The
actuating
positions A and
point

A greater
detrimental
travel
which,
generation
by

NOTE

season.

LEVER

CHECK
FROM
FORWARD

is

not impeded

cable

too

for shift

holes

housing.

transmission

loosening

moved

to

(cable

the

minimum

control
of

the

shift operating lever

with

shifting

lever,

and

3Dmm

amount

and

is

shorter,

in

tum,

and

slow

clutch

Check

TRAVEL

FOR

EQUAL

NEUTRAL

AND

REVERSE.

THRU

or

small a bending

located

Refer

CABLES

any

does

cable

when

the

travel,

between
B should

would

clutch plate

engagement or

for proper

TRAVEL

the

transmission,

by

restricted

rod

linkage,

control

to

is suitable

the

retaining

position

or rod

not

distance

should be

in

neutral position of

as

measured

for

the

of shift lever

is

recommended.

proper

mean

FORWARD

..

B.

by

radius,

cable

connections,

above

the

the

WESTERBEKE

for

screw,

required

linkage).

contact

between

arranged

the

neutral

the

neutral

be

at

least

inner pivot

travel

clutch

engagement

premature

failure.

no

actuating

movability

unsuitably

etc.

shift

cover

single

lever

the

for

the

Make

certain

the

actuating

lever

at a right

position.

on

the

control

the

at

the pivot

position

35mm

point.

is

in

However,

wear,

This

engagement

lever

travel

NEUTRAL

N

make

certain

of

positioned

In

order

use

the

on

parts

remote

actuating

shift

control

that

lever

and

angle

The

console

actuating

point

and

for

the

no

way

if

the

might

excessive

would

be

at

at

the
to

mount

two

top

of

list.

control.

lever

the

cover

cover

neutral

lever.
of

the

end

outer

lever

be

impeded

indicated

all.

least

that

guide

the

can

should

to

the

posi-

should

pivot

heat

each

a

A

CAUTION:

the

actuating

shift

lever

this

mechanism

transmission

*"DRIVESAVER"

lever

travel

warranty

·is

The

pOSition

is

factory-adjusted

from

neutral

is

in

any

way

will

a product of

of

position A and

be

the

mechanism

to

tampered

with,

void.

Globe

Marine, Rockland,

behind

ensure

B.

If

the

equal

MA.

Engines & Generators

39

ACTUATING

LEVER

0.02

MINIMUM

in

(0.5mm)

CLEARANCE

COVER

HURTH

HBW

TRANSMISSIONS

INITIAL

All

with the engine at the factory prior

reasons the
Fill the gearbox with Automatic Transmission Fluid

(Dm{TRON ill). The
mark
dipstick,
after the
sealing ring under the hexhead of the dipstick. Check for
leaks and make a visual inspection of the coupling,
and

CHECKING

OPERATION

HBW

marine transmissions are test-run

fluid

is

drained before shipment.

fluid

level should

on

the dipstick.

do

fluid

hoses,

and shift cables.

not screw

I'

level

To

check the

it

in.

Screw

is

checked and

on

a test stand

to

delivery.

fluid

the

dipstick into the case

tighten.

For safety

be

up

to

the

level, just insert the

Do

not forget the

index

oil

FLUID

LEVEL

i

FLUID

'nm~1

.

FLUID

DRAIN

~~

I

FLUID

Change the
operation, then every
year or at winterizing.

Removing

Push a suction pump hose down through the dipstick hole
the bottom of the housing and suck out the
allows, use the transmission drain). Remove the drain plug

from the bottom

drain into a container, then reinstall the plug with
washer.
the used

recheck the

DRAIN

NOTE:

drain plug sealing
this sealing

CHANGE

fluid

Wipe

fluid.

fluid

PLUG

TORQUE

When

washer.

A

WARNING:

engine

is

running.

stick

hole.

for the first time after about

300 operating

the

fluid

of

the transmission and allow the

down the transmission and properly dispose

After running the engine, shut

level.

20 -25

fI/Ibs

changing

This

the

washer.

Never

Hot

could

fluid,

The

pull

fluid will

cause

take

drain

out

the
splash

severe

hours

or

fluid.

care

not

plug

will

dipstick

from

bums.

25

hours

at

least once a

(If

space

fluid

its

sealing

down

and

to

lose

leak

without

while
the

dip-

the

the

cooler

of

to

to

of

OPERATING

The maximum permissible
2300 (110°).
time.

A

too

high,

transmission

LOCKING

Locking of
required: use the gear shift lever position opposite your
tion of travel for this

position corresponding

WHEN

Rotation of the propeller without load, such

is

being sailed, being

operation of the engine
charging the battery),
transmission

DAILY

o Check
o

Visually

transmission.

o Start the engine in neutral, allowing a

idle

o Shift into

NOTE:

from

the

the

idle

For additional infonnation refer
Transmission Section: SHAFT

NANCEAND

~---

General

Gear

ratio

Lubricating
Transmission

Capacity

Propeller
Direction

TEMPERATURE

ATF

This

temperature

CAUTION:

stop

If

the

the

engine

can

transmission

immediately

fluid.

THE

PROPELLER

the

propeller shaft

UNDER

SAIL

pUIpose.

towed,
will

by

to

the direction of

OR

BEING

or anchored

with

the propeller stopped

have

OPERATION

the

transmission

check the gear shift level linkage

to

warm

the

gear.

Too

low

an

idle

transmission

speed should

TRANSMISSION

HBW

TRANSMISSIONS

~

---

(optional)

Fluid

Sump

Shaft
of

Rotation

fluid.

fluid.

speed will

gear

and

be

increased

(Hurth

Standard

hardened
operated

2.63

: 1

2.99

: 1

2.74: 1 (HBW

ATF -type A or

HBW

150A

HBW

150V

HBW

250

Right

hand -standard

transmission

temperature

only

an

additional brake

Never put the gear shift

should

be

reached

fluid

temperature

and

check

travel

of

not

for

the

TOWED

as

when

in a river,

no

detrimental

few

produce a chattering

damper

to

COUPLINGS,

TROUBLESHOOTING.

(HBW
(HBW

plate.

the following

SPECIFICATIONS

-----

Transmission)

helical

gears,

multiple

disc'

150A -3R)
150v -3R)
250 -3R)

Dextran

0.59

U.S.

1.11·U.S.

0.75

U.S.

as

(for

effects

and

minutes

In

such

text

MAINTE-

--

Case-

with a servo-

clutch.

-

/I

or

III

qts

(0.561

qts

(1.05

qts

(0.79

the

is

the

in

exceed

a short

is

not

direc-

in

the

boat.

boat

well

on

the

at

noise

cases

this

-

liters)
liters)
liters)

as

Engines.&

40

generators

HURTH

TRANSMISSIONS

Operating

A

too
transmission

Normal
should
maximum
reached

Make
to

provide

TRANSMISSION

Coolers

150A,

HBW
The

cooler
prevents
fluid.
will,
leaks.

A

transmission
some
waters,

Temperature

CAUTION:

high,

operating

be

in

temperature of 266°F (l30°C)

for

certain there

good

If

stop

the

guid.

temperature of

the

range

a short

ventilation

the

engine

of

time.
is

enough space

COOLER

are

standard equipment

150V,

and

the

250

35

and

50).

is

a separate part of

any

possibilities of coolant

However,

in

time,

circumstances,

maintenance,

the

continued

erode the inside of

cooler

may

depending on

etc.

transmission

guid

immediately

the

transmission

122°F

(50°C)

to

around

and

cooling.

for

the

HBW

(no

cooler

is

necessary

the

transmission

diluting

flow

of coolant thru

the

cooler

last

ten

years

operating

it might

only

last half

temperature

and

check

fluid

212°F

(l00°C). A

may

be

only

the

transmission

100,

125, 150,

for

which

the

transmission

the

causing

or

more

hours,

external

but,

that

is

the

the

cooler

in
tropical
time.

MAINTENANCE

Transmission
housing
routine,

Periodically inspect
and

corrosion.

Lay-up/Winterize

Storage

o

Drain
with

NOTE:

engine

o

Clean
(use

o Fill

prevent
months

o

Loosen
flange
removing
and

o Inspect

Look
the
moving

NOTE:

(twelve

fluid

before

maintenance

clean,

and

change

requires

water

a proper

This

raw

up

the

heat

resistant

the

transmission

internal
or

attaching

and

the

spray

with

the

for

corrosion

conduit,

parts.

If

the

months

to

prevent

putting

check

the

the

fluid

the

Lubricate

special

from

the

mixture

operation

water

cooling

transmission

paint).

corrosion

more).

hardware

propeller shaft

boat

from

lubricant.

gear

shift

of

and

bending

transmission

or

more),

internal

the

engine

is

minimal.

fluid

level

every

transmission

the

cable

connections.

care.

Follow

transmission

of

antifreeze

will

normally

system

and

touch

with

Dextron

(extended

from

coupling

the

water.

cable,

linkage,

the

end

fittings,

of

the

is

to

be

it should

corrosion.

back

into

Keep

as

part of

300

operating

and

the

these

procedures:

oil

cooler

coolant.

occur

is

properly

up

III ATF

storage

the

transmission

flange

Separate

and

cracks

cable

rods.

stored for a

be

topped

Reduce

service

the

exterior

your

regular

hours.

cooler

for

and

replace

when

the

winterized.

unpainted

fluid

to

only,

twelve

output

before

the

flanges

attachments.

or

cuts

Lubricate

long

offwith

the

fluid

leaks

areas

in

all

time

level

TRANSMISSION

COOLER

TRANSMISSION

""PE'RIO[,U{;ALLY

EROSION

AND

LEAKAGE

INSPECT

FOR

For additional

HURTH
ZF

Industries

3131

S.W.

Fort

Lauderdale,

Tel.:

(954)

information

MARINE

42nd

Street

FL

581-4040

contact:

GEAR

33312

.

Engines. & Generators

41

HURTH

HSW

TRANSMISSIONS

SHIPMENT

For safety
transmission
temporarily attached

Before leaving
undergoes
The residual
draining
against corrosion for at least

"

OIL

The oil
continuous cooling
passes
board.

tubes

WESTERBEKE
A

SPARE

reasons,

fluid

the

a test

run,

fluid

acts

as

a preservative

OUTPUT

COUPLING ~-....

COOLER

cooler,

mounted

through

The transmission

·and

OIL

the

back

into

RECOMMENDS

COOLER

ABOARD

the transmission

during shipment

to

the

WESTERBEKE plant,

with

remaining in

for

the

tubes

the

CARRYING

is

not

filled

and

the

selector lever

actuating

Dextron

one

above

transmission

of

the

fluid

transmission.

shaft.

each

III ATF transmission

the

transmission after

and

provides protection

year if properly

r!!f!!P:~r¥II:,...--

S=~~~~JJ..-

the

transmission, provides

fluid.

cooler

and

discharges

is

cooled

as

it

flows

with

transmission

stored.

AIR

VENT

FLUID

FILTER

Raw

water

over-

around

RAW

WATER

CONNECTION

is

fluid.

the

INITIAL

Set
and
with
shifting should
forward

clutch permits changing at high

reversing at high speeds

After initial operation,
coupling,
the

LOCKING

Locking of
required:
direction of travel for
in
boat.

WHEN

Rotation
boat
well

(for charging
on

NOTE:

gear shift must

idle

DAILY

o Check
o
o Start

o Shift into

OPERATION'

the

shifting lever

let it

run

long

transmission

to

reverse

oil

cooler and

transmission.

THE

the

use

the

position corresponding

UNDER

of

the

is

being sailed, being towed or anchored

as

operation of

the

transmission.

When

the

and

can

free-wheel.

to

neutral position (N). Start

be

enough
fluid.

smooth

in

idle

Shift into

and

are

permissible since

in

the

make

a visual inspection of

hoses,

PROPELLER

propeller shaft

the

gear shift lever position opposite

this

purpose. Never put

SAIL

OR

BEING

propeller without a

the

engine

the

battery), will

boat is

being

be

in

the

neutral position.

OPERATION

the

Visually

the

to

warm

transmission

check

the

engine
the

fluid.

gear.

fluid.

gear shift linkage

in

neutral,

to

fill

the

cooler

gear,

forward

positive. Direct

the

rpm

including

event of

and

by

to

danger.

the

cable connections

an

additional brake

the

direction of travel of

TOWED

load,

such

with

the

propeller

have

no

detrimental

sailed

(engine

The

and

allowing a

few

the

engine

and

hoses

and

reverse;

changes

multiple

stopped),

disc

sudden

the

is

your

the

gear shift

as

when

in a river,

stopped

effects

propeller is at

transmission.

minutes

from

output

to

not

the

the

as

the

at

idle

RAW

WATER

CONNECTION

TRANSMISSION

Fill

the

transmission with

should be

level,

During

output shaft
should be changed after
hours

up

press

the

first

thereafter.

NEUTRAL

These transmissions
switch.

This

Unless

the

transmission selector lever

neutral,

the

FLUID

to

the mark

the

dipstick

25

operating

and

transmission cooler

SWITCH

are

is

to

prevent

engine starter will not

TRANSMISSION

Dextron

on

into

the

equipped with a

the

OIL

III

the

dipstick. After checking

the

case

and

hours,

inspect

for

first

25

hours

engine

from

activate.

COOLER

ATF.

The

fluid

turn it

to

the

bell

leakage.

"neutral

is

perfectly aligned

and

every

starting

The

safety

level

the

tighten.

housing,

fluid

300

in

gear.

in

Engines & Generators

42

NOTE:

Too

low

an

idle

speed will produce a

from

the

transmission gear

the

idle

speed should

Operating

The operating temperature of
exceed
is

provided.

reach 220°F

A

too

Temperature

176°F

At

(104°C).

CAUTION:

high,

stop

transmission

be

increased.

(80°C).

A connection for a temperature

maximum output of the

If

thl1

transmission

the

engine

fluid.

and

damper

the

plate.

transmission should not

engine,

fluid

immediately

and

chattering

In

temperature

check

such

the

probe

fluid

the

noise

cases

may

is

HURTH

HSW

TRANSMISSIONS

CHANGING

ACTUATING

LEVER

16mm

(8")

SCREW

THE

TRANSMISSION

FILTER

ELEMENT

HSW

FLUID

MODEL

450

Replacing

Pour

in

with

the

Transmission
coolers, length of hoses

Reinsert
and

tighten

NOTE:

a

screw

After

A

engine

hole.

the

Fluid

new

Dextron

dipstick.

fluid

quantities will

Approximate Quantities

HSW450 -2.12
HSW630 -3.2
HSW630V

the

filter assembly into

the

Allen

Some

HSW transmissions

on

their filter

running

WARNING:

is

running.

This

could

the

engine,

Never

cause

III.

ATF

and

- 4.2 quarts

screw.

assemblies.

Hot

MAINTENANCE

Transmission maintenance

clean,

check

housing
routine,

Periodically inspect
and
checking

(fluid

and

change

corrosion. Make certain

the

fluid

will appear

the

the

fluid

the

transmission

level look for

as

strawberry cream).

fluid

and

vary

the

angle

of

quarts

(2.0

quarts

(3.0

(4.0

the

housing. Press it

use

a "T" handle

shut

down

and

pullout

"uid

severe

fluid

the

dipstick

will

splash

bums.

is

minimal.

level

as

every 300 operating

and

the

air vent

signs

check

the

quantity

with

the

use

of

the

transmission.

Liters)

Liters)

Liters)

in

place

in

place

of

recheck

Keep

part of your regular

of water contamination

from

the

is

clear

the

while
the

the

exterior

cooler

and

fluid

level.

the

dipstick

hours.

for

leaks

when

Filter

Element

The

Hurth

HSW transmission

opposite
the

Remove
a

Twist

the

it clockwise. Check

necessary.

local

Removing

Push
the

Remove
to

Wipe
fluid.

the

dipstick.

fluid

is

changed.

the

filter

6mm

Allen

and

pull out

new

filter

Replacement

WESTERBEKE

the

a suction

filter)

to

the

the

oil return line

drain

into a

down

the

wrench.

onto

Fluid

pump

bottom of

container,

transmission

This

by

loosening

the

filter

the

cover

the

O-rings for

dealer or ZF

hose

has a filter

filter

must be replaced whenever

the

and

remove

and

lock

filters

can

down

through

the

housing

from

the

then reconnect

and

screw

the

it

into place

damage

be

obtained

(Hurth

and

cooler

properly

element located

on

the

the

dispose

the

cover

using

element. Place

by

turning

and

replace if

from

your

dealer).

pipe

hole

(under

suck out

and

oil return

allow

of

the

the

line.

the

fluid.

oil

used

Lay-up/Winterize

Storage requires special

D Drain water

with

NOTE:

engine

D

Clean
(use

D Fill

the
vent internal corrosion (extended storage
months

from

a proper mixture of antifreeze

This

operation will normally occur

raw

water cooling system is properly

up

the

heat resistant paint).

transmission with

or

more).

D Loosen attaching hardware

flange

and

propeller shaft coupling

removing

and

D Inspect

Look for corrosion of
the

all

NOTE:

(twelve

fluid

before

the

spray

with lubricant.

the

gear shift cable, linkage,

conduit,

moving

and

parts.

If

the

transmission is

months or

to

prevent internal

putting

care.

the

transmission

transmission

boat from

the

bending of

more),

the

engine back

Follow these

and

touch

Dextron

from

the

water.

end

fittings,

the

to

be

it should

corrosion.

into

procedures:

oil

cooler

and

coolant.

when

winterized.

up

unpainted

III ATF

the

Separate

actuator

stored for a

fluid

only,

transmission output

flange

before

the

and

attachments.

cracks

rods.

be

topped offwith

Reduce

the

service.

replace

the

areas

to

pre-

twelve

flanges

or

cuts

Lubricate

long

time

fluid level

in

Engines & Generators

43

HURTH

HSW

TRANSMISSIONS

CABLE

The
Upon
illustration)
control elements
actuating lever
distance between
(O.5mm).

The control cable or

to
tral
should coincide
transmission.

The shifting travel,

actuating lever between
A

1-3/16in

CONNECTIONS

transmission

loosening

the

actuating lever

position of

and

B,

should be at least 1-3/8in

(3Omm)

is

the

can

be

(cable

does

the

the

with

for the inner pivot

suitable for a single lever gear
retaining

moved

not contact

lever

rod

when

gear shift lever

the

as

screw,

the

actuating lever

to

any

position required

or

rod

linkage).

the

and

the

should be arranged at a right

in

the

neutral position of

measured at

the

neutral position

Make

certain that

lever

hub:

the

hub

should be

neutral position. The

on

the

control console

the

the

pivot point of

and

(35mm)

for

point.

N

shift.

for

minimum

O.02in

lever

the

end

positions

the

outer

(see

the

angle

neu-

on

the

the

and

SHAFT

WESTERBEKE
the
flexibly

deflections.

bearing

absorbed
specified under
However,
additional
torsional vibration. When using a universal joint
certain

Even
coupling or
box bearings caused
boats or where
coupling

NOTE:

shifting
or
small a
mount a support for shift
two
the

COUPLINGS

recommends a

transmission

mounted,

is

to

with

When

is

rod

linkage,

bending

threaded

gear

and

the

propeller shaft

in

order

to

compensate

The installation of a special propeller thrust

not required, since

by

the transmission bearing, provided

SPECIFICATIONS

the

output shaft should

loads.

Special care should

observe

and

not impeded by restricted movability

housing.

the

the engine solidly mounted

"DRIVESAVER"

by

the

distance between

stem gland

installing

by

unsuitably positioned

radius

holes

located

Refer'to

the

manufacturer's instructions.

will reduce

hull distortions, especially

is

less

the

transmission,

or other

control

on

the

flexible

than

restrictions.

the

WESTERBEKE

connection

if

the

for

propeller thrust

is

not

exceeded.

be

protected

be

taken

the

use

stress

the

transmission output

about

8oomm.

make
guide

In

cable

connections,

cable

bracket

engine

angular

to

between

will

the

value

from

prevent

shaft,

of a

flexible

in

the

in

certain

of

the

sheaves,

order

use

mounted

parts

list.

is

be

make

gear­wooden

that

cable

too

to

the

on

A greater
detrimental
is
which,
generation
by

CONTROL
TROUBLESHOOTING)

NOTE:

season.

A

the
shift
this
transmission

amount

shorter,

in

turn,

slow

clutch engagement or

Checkfor proper actuating lever

CAUTION:

actuating

lever

mechanism

of actuating lever travel

and

is

recommended.

proper clutch engagement might

would

mean

and

clutch plate

CABLES

travel

The

lever

from

is

under

position

is

factory-adjusted

neutral

in

any

warranty

ACTUATING

LEVER

However,

premature

failure.

This

no

engagement

TRANSMISSION

of

the

position

way

tampered

will

be

void.

is

in

no

way

if

the

lever travel

be

impeded

wear,

excessive heat

would

be indicated

at

all

travel

at least

mechanism

to

ensure

to

A

and

with,

the

'..".,./WESTERBEKE

For additional information

(see

each

behind

equal

B.

If

I Enaines & Generators

HURTH
ZF

Industries

1018

Carolina Drive

West

Chicago,

Tel.:

(874)

contact:

MARINE GEAR

IT...

60185

634-3500

TYPICAL

STEERING

STATION

44

CONTROL

The
improper
problems
rather

HURTH

cable

If

you
shut
level,
the

full
tral,
observe
is

stiff
and
excessively

CABLES

majority

the

into

try

of

clutch

with

than

from

clutches,

adjustments.

experience

engine

then

have a helper

range -from

full

reverse,

the

actuating

to

operate,

again.

If

tight

Problem

Transmission
Fails

Transmission
fails.to

.

Delay
only

Transmission

Chattering
mainly

Boat

Oil

Leakage.

to

move

propel

of

gear

after

an

transmission

at

low

fails

to

attain

gears
into

shifts

the

engagement

increase

noise

engine

transmission

adjustments

control

cables

problems

in

particular,

operating

down.

First

neutral

and

lever

break

the

it

is

still

bends,

and

cannot

be

gear.

into

gear,

boat.

or

in

speed.

becomes

noise,

speed.

specified

max.

TRANSMISSION

difficulties

(manual

(hydraulic

with

problems

check

move

the

to

back

to

on

the

cable

stiff,

check

check

shifted.

but

engages

louder.

speed.

the
are

arise

as a result

transmissions)

transmissions)

transmission

very

sensitive

with

the

the

transmission-fluid

cockpit

full

shift

forward,

neutral -while

transmission.

loose

at

the

transmission

the

cable

any

linkage

,

Probable

1.

Actuating

2.

Shifting
unattached.

3.

Actuating

cover

1.

Output
Propeller

2.

Output

Output

3.

propeller

1.

Actuating

equal

to N to

2.

Actuating

Actuating

3.

1.

Damage

to

wear

ment

between

Beginning

2.

mission
without
transmission,

The

engine

1.

vibrations
a

"chattering"

1.

Operating

Operating

2.

Corrosion

1.

Damage
Misalignment

2.

plate.

TROUBLESHOOTING

of

or

itself.

to

improper

transmission,

lever

through

back

to

neu-

you

If

the

remote

for

kinks

or

for

binding.

Cause

lever

is

loose.

cable

is

broken,

Cable

radius

lever

is

binding

coupling

is

not

tuming.

shaft

is

not

coupling

coupling

shaft

lever

lever

lever

starting

or

fatigue,

damage

due

fluid,

in

temperature
without
at

sealing

turning.

is

tuming.

and

are

tuming.

travel N to B not.

A.

travel

is

is

binding

on

flexible

possibly

engine

and

of

bearings

to

torsional

overload,

or

excessive

or

propeller

the

drive

unit

noise

in

the

cooling.

radial

sealing

ring.

of

output

If

have a helper
the

it isn't

authorized

bent

or

is

too

severe.

against

the.

insufficient.

against

cover

coupling

due

to

transmission.

in

trans-

vibrations,

wrong

alignment

engine

generates

is

flanges.

torsional

which

produces

transmission.

high.

ring

and

A

new

cable
needed.
out of
make

While

gear

sure

the

transmission

propeller

needs

professional

thrust,

check

the

shaft

or,

stuck

NOTE:

lfyou

immediately

1.

2.

3.

1.

2.

3.

1.

2.

plate.

3.

due

misalign-

running

output.

1.

2.

of

1.

2.

1.

2.

shaft.

1.

2.

and

perhaps a new

the

cable

using

the

there's

no

passes

put

it

in

shaft;

if

attention.

to

see

you

if

you

have a folding

in

the

"no

suspect

contact

marine

transmission

Tighten

damping

Check

the

Detach

the

hand.

Clearance

Transmission
The

coupling

on

the

propeller

pins

and

Inspect

the

A

folding

propeller

Adjust

cover

See

ACTUATING

Check

shift

DIAGRAM.

Check

clearance,

Check

alignment,

inspect

the

engine.

Replace

Transmission

Mount a flexible

between

the

a

higher

stiffness

Inspect

the

transmission.
Wrong

type

Check

cooler.

Transmission

Check

alignment.

[HURTH]

linkage

is

loose,

lever

on

the

binding

the

a major

your

inside

these

tests,

forward

and

shaft

isn't

If

it

still

have a propeller

pitch"

position.

problem

WESTERBEKE

facility.

Verification/Remedy

bolt

on

cable,

reattach

shift

cable

and

should

beO.02

needs

professional

bolts

are

sheared

shaft.

bolts

may

be

in

"no

plate

until

LEVER

cable

adjust

inspect

plate

if

necessary.

needs

coupling

and

factor

plate

Replace

fluid.
Inspect
needs

Must

Tighten

as

it

may

be
pitch"

the

TEXT

length.

if

professional

transmission; a coupling
might

if

necessary.

Use

coolant

professional

be

coupling

propeller;
propeller
may

lever

damper

engine

damper

of

mechanism

shift

the

side

of

the

case.

crank

reverse

turning,

does

tum

or

feathering

in

actuating

lever.

or

replace.

operate

the

in

(0.5mm).

attention.

or

the

or

replace

necessary.

be

missing

jammed. A variable

position.

lever

is

exact

AND

See

ACTUATING

necessary.

flexible

coupling.

between

the

attention.

with

another

be

sufficient.

between

the

ATF

Dextron

hoses

attention.

within

0.003

transmission

the

transmission

the

engine

while

you

the

transmission

but

there's

on

the

propeller,

your

transmission,

dealer

or

actuating

lever

coupling

is

set

screws,

or

damaged.

pitch

mid-position

DIAGRAM.

LEVER

If

noise

transmission

stiffness

factor

engine

and

III,

check

fluid

and

coolant

in

(O.OBmm).

may

in

and

observe

no

end

of

an

by

Slipping

keys,

.

persists,

and

the

with

the

level.

flow.

be

and
to

that

Engines. & Generators

45

TRANSMISSION

·TROUBLESHOOTING

Chattering
mainly

Transmission
fails

NOTE:

transmission

at

low

to

propel

lfyou
immediately
authorized

Problem

engine

shifts

into

the

boat.

suspect

contact

marine

noise,

speed.

gear,

but

a major

your

WESTERBEKE

transmission

problem

facility ..

1.

The
vibrations
a

"chattering"

1.

Output

2.

Propeller
Output

3.

Output
propeller

in

your

dealer

Probable

engine

or

propeller

in

the

noise

coupling

shaft

is

coupling

coupling

shaft

are

Cause

drive

is

is

and

transmission,

or

an

unit

in

the

not

turning.

not

turning.

turning.

turning.

generates

torsional

which

produces

transmission.

Mount a flexible

1.

between

a

higher

1.

Transmission
The

coupling

2.

on

the

propeller

pins

and

3.

Inspect

A

folding

Variable

Verification)Remedy

coupling

with

the

engine

stiffness

needs

bolts

coupling

the

propeller;

propeller

pitch

propeller

and

factor

professional

are

shaft.

bolts

may

another
transmission; a coupling
might

be

sheared

or

TIghten

or

as

necessary.

it

may

be

missing

be

jammed.

may

be

in

stiffness

sufficient.

attention.

the

coupling

replace

set

or

"no

pitch"

factor

with

is

slipping

screws,

keys,

damaged.

position.

Engines & Generators

46

BORG

WARNER

VELVET

OPTIONAL

DRIVE

TRANSMISSION

SHIFT

The
the

(F), Neutral (N),

ball
to
the
actuating lever
improperly
the
actuating
ensure

TRANSMISSION

LEVER

gear shift control

actuating lever

located behind

center

helm

transmission. The shifting mechanism

proper

POSITION

mechanism

on

the

transmission exactly

and

Reverse (R) shifting

the

transmission lever must

the

lever

in

each

position. The gear

must

be

coordinated

through

adjusted shift mechanism

lever should

operation.

with

shift mechanism

be

free of dirt

and

those

can

and

linkage

must

in

positions.

shift

of

the

adjustments.

cause

and

transmission

well

lubricated

position

Forward

A detent

work

freely

positions

Velvet

damage

at

Drive

An

to

to

SHIPMENT

For

safety

reasons,
transmission
is

temporarily

Before leaving
undergoes
fluid.
draining
against

a test

The

residual

acts

corrosion

TRANSMISSION

Check

the

transmission fluid level
transmission
continue
operation,
output shaft
changed
300

A

and
starting

to

keep

after

operating

CAUTION:

the

correct

the

the transmission

fluid

during shipment and the selector lever

attached to the actuating

the

WESTERBEKE plant, each transmission

run,

with

fluid remaining

as

a preservative and provides protection

for at least

FLUID

has

not

been filled,

use

this

fluid.

a lookout for

and

transmission

the

first

25

hours

thereafter and/or at winter lay-up.

Be

certain

size

cooler

engine.

is

not filled with

Dextron

During the first

hours

III ATF transmission

in

the

one

year

if

on

the

fill

with

any

leakage at

cooler.

This

and

approximately every

the

transmission

is

properly

VELVET

,

TRANSIV!ISSION.

shaft.

transmission after

properly

dipstick.

Dextron

installed

stored.

If

the

III and

25

hours

of.

the

bell

housing,

fluid should be

is

filled

before

WARNER

DRIVE

Shifting

Place
Shifting
tion
order.
speed.
allow

Into

Gear

the

gear shift

from

one

may

be

made

Shifts should

Start

the

engine

the transmission

in

Neutral

selector position

at

any

time

be

made

and

set

fluid

Neutral

Move

the

gear shift lever to

feel

the

detent.

This

centers

the
mission.
completely
sion

NOTE:

switch.
aligned

With

interrupted

does

not turn.

Some

Unless

in

neutra~

the

control

and

transmissions

the

transmission

the

engine

in

the

are

Forward

Move

the
feel
the

forward

move

gear shift lever

the

detent.

the

boat

The

position.

in a forward

to

actuating

The

output shaft

direction.

Reverse

Move

the

gear shift lever

feel

the

detent The

the

reverse position. The output shaft

should

move

the

boat

NOTE:

Position

always

the

gear
engine!
of

the

actuating

Moving

to

away

shift

This

the

Forward

from

control

problem

lever

to

actuating

in

a reverse direction

transmission

is

always

the

engine.

in

the

forward

may

be a result

by

the

before starting

to

another selector

below

1000

at the lowest

the

throttle at

to

warm

up

the

middle

actuating lever

this

position,

output shaft of

equipped

actuating

starter

will

the

forward

lever·

on

the
and

the

reverse

lever

on

the

and

actuating

toward

the

If

boat

moves

position,

of

gear shift

lever.

the

engine.

rpm

and

practical

idle

speed;

for a

few

minutes.

position.

You

on

hydraulic

the

the

transmis-

with a neutral

lever

is

perfectly

not

activate.

position.

position.

the propeller

lever

You

transmission

the

propeller

You

transmission

(astern).

from

engine.

Reverse

backwards

shut

off

incorrect

movement

posi-

in

any

engine

should

trans-

power

safety

should

is

shaft

should

is

Neutral

with

the

is

in

in

is

Engines ~ Generators

47

BORG

FORWARD

TRANSMISSION

DAILY

OPERATION

o Check the transmission
o

Visually

o Start

for

NOTE:

noise

such

o Shift

check the gear shift linkage

the

engine

the

fluid

Too

from

cases

into

gear.

ACTUATING

in

to

Waml.

low

an

idle

the

transmission

the

idle

neutral.

speed should

WARNER

NEUTRAL

LEVER

fluid.

Allow a

speed will

gear

VELVET

REVERSE

POSITIONS

and

transmission.

few

minutes

produce a chattering

and

damper

be

increased.

at

plate.

idle

In

DRIVE

o

o

o

o
o

A

engine
hole.

Oil

Approximately
sions
have
will
angle
oil

TRANSMISSION

Clean

off

used

fluid.

Refill

the
quantity
and

the

Check

the

Replace

into

place

Run

the

WARNING:

is

running.

This

Capacity

to

the

a direct relationship

be required

of installation

required

the

transmission

transmission

will

vary

installation

dipstick

the

oil

filler

and

turn

engine,

could

oil

to

2.5

level

to

fill

shutdown

Never

Hot

cause

quarts

fill

fill

will

the

and

with

DEXTRON

depending

angle.

for

cap

clockwise

pullout

Ruid

severe

mark

the

make a difference

transmission.

on

FilI

through

the

proper

and

dipstick.

until

and

recheck

the

will

splash

bums.

(2.36 liters)

on

the

to

the

oil

oil

cooler

properly

the

transmission

fluid

finger-tight.)

dipstick

from

will

dipstick.

capacity.

and

the

dispose

III

ATF.

the

dipstick

level.

(Press

the

the

fluid

while
the

fill

most

Many

Additional

cooler

in

the

of

the

The

model

hole.

dipstick

level.

the

dipstick

transmis-

variables

oil

lines.

quantity

The

of .

A

CAUTION:

cause

damage

throttle

on

back

the

transmission

Shifting

to

the

to

idle

gears

engine

when

and

the

above

damper

shifting

damper

INSPECTION

o

Visually
Check
worn.

check

for

wear

for

oil

leaks

at the

on

the hydraulic lines

o Lubricate the detent ball and shift
o Inspect

o Inspect

A

sion
positions.

CHANGING

After
be

changed
ter haul-out
becomes

o

Remove

o

Remove
drain

o Reconnect the
o

Use a suction
through

the

shift linkage.

the

transmission bolts; retorque

CAUTION:

shift

the

initial 50 hour change, the

contaminated,

into a container.

Clutch

failure

lever

does

not

THE

TRANSMISSION

at

every

300 operating

However,

the
the

the

the

changes

oil

filler

cap

oil

cooler return line

oil

cooler return

pump

to

filler

cap/dipstick

fully

fluid

remove

will

engage

must

color,

and

dipstick.

hours

line.

the

hole.

1000

rpm

plate.

Pulling

gears

will

plate;

hydraulic

and

replace

cable

attachments.

if

necessary.

occur

if

the

the

detent

FLUID

transmission

thereafter

be

changed

or

smells

and

allow

transmission

can

the

save

wear

connections.

if

transmis-

ball

fluid

should

or

at

win-

whenever

rancid.

the

oil

to

oil

it

DIPSTICK

MAKE

RUBBER
SCREWED
TIGHTTOTHE

HANDLE

Oil

A
mended.

ture

PRESSURE

An

the
transmission
gear

constant.

_----r.

CERTAIN

Temperature

maximum

exceeds

optional

control

should

THE

SEAL

IS

.

oil

Discontinue

230

GAUGE

mechanical

panel

fluid. A normal

indicate 95

temperature

operation

0

P

(1

10°C).

pressure

to

constantly

-120

FLUID

FULL

of 190°F (88°C)

anytime

monitor the

reading

Ib-in

gauge

at 2000

2

(6.7 - 8.4

sump

can

pressure

LEVEL

is

recom-

oil

be

installed

rpm

kg-cm

tempera-

at

of

the

in

forward

2

)

and

be

Enl1ines & Generators

48

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission maintenance
housing clean, check the

and

will

change the

Make

the

fluid

appear

level look for

as

routine,
Periodically inspect the transmission

and

corrosion.
checking
(fluid

is

minimal.

fluid

level

fluid

every

certain the air

strawberry

cream).

signs

Lay-up/Winterize

Storage

D

D
D Fill

D

D Inspect the gear shift

requires

Drain
replace it

NOTE:

raw

water cooling system

Clean
(use

heat resistant

the

prevent internal corrosion.

12

months

Loosen
output
removing
and

spray

Look
the

conduit,

all

moving

NOTE:

(twelve

to

fluid

before

special

care.

the

water

from

with

a proper

This

operation

up

the

transmission

paint).

transmission

or

attaching hardware

flange

the boat

with

for

corrosion of the

and

parts.

If

the

transmission is

months or

prevent internal

putting

with

more).

and

propeller shaft

from

lubricant.

cable,

bending of

more),

the

engine

the

mixture

will

corrosion.

Follow

transmission

usually
is

properly

and

touch-up

Dextron

(Extended

from

the

water.

linkage,

end

fittings,

the

to

be

it should

back

Keep

the

exterior

as

part of your regular

300

operating

and

the

cooler

vent

is

clear

and

of

water

contamination

these

procedures:

oil

cooler

of

antifreeze

occur

III ATF

the

transmission

coupling

Separate

and

actuator

stored for a

be
Reduce

into

service.

coolant.

when

winterized.

unpainted

fluid

storage

flange

the

attachments.

cracks

or

rods.

topped offwith

the

hours.

for

leaks

when

and

the

engine

areas

to

only,

before

flanges

cuts

in

Lubricate

long

time

fluid

level

WARRANTY

Service
dealer.

For

assistance,

BORG
200
New
Tel.:

BORG

placed

ation

or
Therefore
made

at

ca~sed

A

CAUTION:

occur
resulting
BORG
related

If

any

problems

TRANSMISSION

NOTES

manuals

contact:

WARNER

Theodory

Bedford,

(508)

WARNER

on

its

gears

fully

reversing of

torque

low

engine

by a shock

at

low

engine

in

damage

WARNER

torsional

occur

are

available

Rice
MA02745

979-4881

is

aware

as

the

loads

speeds.

load,

System-related

speeds
to

is

not

vibration

TROUIJLESHOOTING

from

Blvd.

of

the

shock

result of

the

and

any

mechanical

propeller

directional

If it

is

found

warranty

noises

which

the

engine

responsible

of

this

with

the

transmission,

your

claim

can

and/or
for
type.

BORG

WARNER

loads

that

propeller

blades

while

changes

should

that a failure

will

be

or

vibrations

cause

gear

transmission.

total

system-

see

in

this

manual.

can

shifting.

denied.

rattle

be

oper-

be

was

can

OIL

COOLERS

The

continued

time,

erode

the

occur.

These internal cooler

following

1.

2.

Either

1.

2.

two

Transmission

and

be

discharged

A

loss

of

fail.

The

raw

water

ing

an

increase

fluid

will

will

eventually

case

requires
Install a
Refill

new

the transmission

flow

of raw water

inside of

problems:

transmission fluid

appear

oil

fluid

will

overboard

will

leak

in

transmission

as

strawberry

fail.

an

immediate

cooler.

the

with

cooler

leaks

leak

into

through

causing

will

cause

into

the

flow

through

will

cause

the

transmission

fluid.

This

cream.

response:

DEXTRON

the

cooler

cross

one

of

raw

the

engine

the

transmission

contaminated

The

transmission

III

ATF.

will,

in

leaks

to

of

the

water
exhaust.

to

fluid

caus-

Engines & Generators

49

If

water

has

contaminated

needs

to

be

cleaned

take

several
Check
mission
the

fluid

If

the

need
A

transmission

some

waters,
WES1ERBEKE

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

transmission

to

the

cooler.

shift

properly,

transmission

last

ten

years

on

operating

it

might

only

having a spare

transmission

with

fresh

the

contamination.

it

appears

filter

it

will

or

more

last half

fluid.

as

pure

and

clean

most

service

but,

hours,

that

cooler

fluid

It

will

trans-

out

likely

facility.

in
tropical
time.

aboard.

LAY-UP & RECOMMISSIONING

General

Many

owners

including

season
accomplish

The

procedures

own

lay-up

others

if

These

engine/generator
you

with

If

you

your

local

provide

Propeller

The

transmission

be

opened
out of
storage
severe
the

boat

shaft

has

apply

to

not

in

period of

Fresh

A 50-50 solution of antifreeze
mended
This

solution
depending
make

sure

Should
from

the

Operate

ture

of

system.

Lubrication

With

the
sump.
with

new

ENGINE

"engine
Run

the

sure

there

rely

on

their boatyards

engines

or

for

do

procedures

its

have

assistance.

the

water or

in

strain

is

actually

small

use,

time.

Water

for

more

engine block

the

the

Then

and

generators,

long

periods

lay-up

preparation

which

and

recommissioning, or

the

procedures.

should provide protection

during a lay-up

maintenance

any

questions

servicing

Shaft

and

up

and

the

the

cradle.

on

the

taken

out or put

been

boats

unless

they

Cooling

use

in

the

may

require a higher

on

the

area's winter

the

antifreeze protection

antifreeze

engine

antifreeze concentration throughout

recheck

of

follow

needs.

regarding

dealer.

He

Coupling

propeller half couplings
bolts

removed

moved

from

The flexibility of

propeller shaft or coupling or

in

bent

that

are

have

Circuit

fresh

be

needed,

and

add a more

to

ensure a complete circulation

the

antifreeze solution's

System

engine

warm,

drain

Remove

and

replace

oil.

Use

the

LUBRICATING

oil

change".

engine

and

check

are

no

leaks.

correct

OIL

for

to

prepare

for

lay-up

inactivity.

themselves.

will

will

allow

and

be

Others

you

will

also

lay-up

more

serve

help

[Propulsion

when

land

to

water,

the

the

water.

In

by

these

strains.

hauled

out of

been

dry for a considerable

[Propulsion

and

distilled water

water cooling

concentration

climate.

drain

all

the

the

oil

grade

pages

proper

Check

is

adequate.

an

concentrated

engine

filter

and

of

oil.

in

this

oil

pressure

system

Refer

their

during

the

prefer

to

perform
as

a checklist

for

your

familiarize

procedures,

than

willing

Engine]

should

the

boat

is

and

during

boat

often

both,

some

cases,

This

does

the

water

Engine]

is

recom-

at

of

antifreeze,

the

solution

appropriate

and

the

cooling

strength.

oil

from

fill

the

sump

to

the

manual

for

and

craft,

off-

to

your

call

to

always
hauled

puts

a
while
the

not

when

all

times.

amount

mixture.

mix-

the

oil

make

to

Fuel

System

Top

off

your

or

higher. A fuel
stabilizer should be
gasoline/water separator
Re-install
up

any

spilled

Fuel

System

Top

off

your

such

as

BWBOR

control

algae

that

the

additives
filter/water separator
in

your

primary
has

one,

Change
fuel
for
system.
the
needed.
allow
equipment

Raw

Close
hose
gallon
check
the

any

zinc
Start

fresh

stop
solution slightly stronger
protection

Start

through

the

water circuit

as

Remove

antifreeze

Examine

cover

until

the

system,

5 -

10

Check

fuel

system

movement

Water

the

from

bucket of clean

the

engine

zinc

anode

the

water

the

the

engine.

providing corrosion protection.

gasket.

recommissioning, but replace

[Gasoline]

fuel

tanks

conditioner

and

make

fuel.

[Diese~

fuel

tanks

and

and

condition

used

fuel

and

clean

the

fuel

filter elements

as

needed.

minutes

Operating

on

for

during

of

the

to
any

the

engine.

Cooling

through-hull

the

fitting.

zinc

anode

and

clean

debris

from

is

located.

engine

and

through

engine

and

in

your

area.

engine

and

the

raw

water

This

antifreeze mixture should protect

from

freezing

the

impeller

mixture

the

will

impeller.

Do

not replace

with

added.

and

certain

with

STABIL

are

used

filter/water

separator sediment

Start

make

leaks
this

engine

the

treated

Circuit

fitting.

Place

fresh

found

or

replace it

inside

Clean

allow

the

system.

refill

the
than

allow

system.

from

accompany

Get

unleaded gasoline of

such

as

STABIL

Change

compatible

in

sure
servicing, correcting

the

the

all

during

your
a replacement, if

the

clean

the

there

are

no

No.2

diesel

should be

the

fuel.

Care

the

system.

separator,

on

the

the

engine

no

air

that

may

for

5 -

10

fuel

through

Remove

end

of

water.

Before starting

in

the

primary

as

required

the

heat exchanger

the

raw

water

raw

water

When

bucket

with

needed

of

this

mixture

Once

the

the

raw

water

it,

the

impeller

the

element in

metal

leaks.

fuel.

added

should

with

the

Change

if

bowl.

engine

and

is

left

have

been

minutes

the

the

raw

this

hose

heat

strainer.

pump

the

bucket

an

for

winter

bucket

winter

pump

so

catch

(into

cover

89

gasoline

your

bowl.

Clean

Fuel

additives

at

this

be

taken

primary

the

the

fuel

and

bleed

allow

it

in

the

fuel

created

them

will

injection

water

into a five

the

exchanger

and

also

where

to

draw

is

empty,

antifreeze

freeze

to

be

drawn

is

empty,

the

lay-up,

(some

it

in a bucket).

needed,

the

pump)

and

gasket.

octane

time

fuel
element
system

the

to

run

in

as

help

intake

engine,
clean

the

the

stop

raw

as

well

and

a

to

on

A

CAUTION:

oil

in

the
combustion
chemicals
internal

parts.

sump

over

deposits

which

Do

can

not

the

leave

the

lay-up

combine

reduce

the

engine's

period.

to

produce
life

Engine

harmful

of

your

old

engine

oil

and

engine's

Intake

Place
opening
shove
recommissioning,
you
note
exhaust

Engines & Generators

Manifold

a clean

of

the

may

need

to

remove

port

50

cloth,

the

intake manifold

cloth

out of

and

assistance of

the

can

be blocked

and

Thru-Hull

lightly soaked

to

sight.

(If

an

attempt

the

cloth prior

in

to

the

Exhaust

in

lubricating

block

the

it

is

not

visible

is

made

servicing

start-up. The

same

manner.

opening.

at

to

start

dealer).

thru-hull

oil,

the
Make

in

the

Do

not

engine,

a

LAY-UP & RECOMMISSIONING

Starter

Lubrication and cleaning

able,
sure the battery connections are shut off before attempting to

remove the starter. Take care in properly replacing any elec-

trical connections removed from the starter.

Cylinder

If

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

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

NOTE:

months
complete
tion
sticking

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the
opening
shove the cloth out
recommissioning, and an attempt is made to start the engine,
you may need the assistance
note to remove the cloth prior to start-up. The through-hull
exhaust port can be blocked in the same manner.

Intake

Clean the filter screen in the flame arrester, and place a clean
cloth lightly soaked in
block any opening. Also place an oil-soaked cloth in the
through-hull exhaust port, Make a note to remove cloths prior
to start-up!

Transmission

Check or change fluid in the transmission as required.

engine is to
sion to the very top to prevent corrosion.
its
and touch up unpainted areas. Protect coupling and output
flange with an anticorrosion coating, Refer to the

Motor

of

the starter drive pinion is advis-

if

access to the starter pennits its easy removal. Make

Lubrication

you anticipate a long lay-up period (12 months

If

engine

storage

or

beyond,

turns

every

pump components

during extended storage periods.

Manifold

of

the intake manifold to block the opening. Do not

Manifold

[Propulsion

be

layed up 12 months

normal

at

recommissioning. Wipe off grime and grease

[Diesel]

Squirt light

or

injectors.

if

removing the injector

is

going

to

be

a lengthy

it

is

wise

to

rotate

the

engine

additional 4 months

to

move.

This

and

Thru-Hull

of

sight.

(If

it is not visible at

of

a servicing dealer.) Make a

to

allow

will help prevent their

Exhaust[Diesel]

[Gasoline]

lube, oil around the flame arrester to

Engine]

or

more, fill the transmis-

Lower the fluid to

or

one,

by

more)

12

hand

the

two

injec-

If

the

TRANSMISSION SECTION in this manual for additional

infonnation.

SPARE

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

PARTS

SPARE

PARTS

section

if

external items such as drive

of

this manual.

RECOMMISSIONING

The recommissioning
seasonal lay-up generally follows the same procedures as

those described in the

section regarding preparation for starting and nonnal starts.

However, some
counteracted before starting the engine.

1.

Remove any rags that were placed in the exhaust, intake
manifold, or flame arrester.

2. Remove the raw water pump cover and gasket and discard
the old gasket. Install the raw water pump impeller
removed during lay-up (or a replacement,
Install the raw water pump cover with a new cover gasket.

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

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

5. Check the condition
circuit and clean
that it is not necessary to flush the antifreeze/fresh water
solution from the raw water coolant system.
engine is put into operation, the system will self-flush in
a short period
up the heat exchanger ends and clear out any accumu­lated debris.

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

[Propulsion

7. Make certain all electrical connections and switches are

in the correct position and there are no-loads on the
generator at start up.

8. Start the engine in accordance with the procedures

described in the
section

of

this manual.

of

your WESTERBEKE engine after a

PREPARATIONS

of

the lay-up procedures will need to be

FOR

STARTING

if

required).

[Gasoline]

of

the zinc anode in the raw water

or

replace the anode as needed. Note

When the

of

time with no adverse affects. Also open

if

it

had been topped off

of

the fluid to nonnal.

Engine]

[Generator]

PREPARATIONS

FOR

STARTING

Batteries

If

batteries are to be left on board during the lay-up period,
make sure they are fully charged, and will remain that way,
to prevent them from freezing.
the batteries will
be subjected to severe environmental conditions, remove
the batteries and store them in a warmer, more compatible
environment.

not remain fully charged, or that they will

If

there exists any doubt that

Engines & Generators

51

STANDARD

AND

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

Feet

(ft) x .305 = Meters

Miles x 1.609 = Kilometers

METRIC

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles

CONVERSION

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

1

Minute

of

Latitude

Latitude = 60

VOLUME

Cubic

Inches

(in3) x 16.387 = Cubic
Imperial
Imperial
Imperial
Imperial
Imperial
Fluid
US
US
US

Pints

(IMP

Quarts

(IMP
Gallons
Quarts

(IMP
Gallons

Ounces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

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

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

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

pt) x .568 = Liters

qt) x 1.137 = Liters

(IMP

gal) x 4.546 = Liters

qt) x 1.201 = US

(IMP

gal) x 1.201 = US

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kilopascals

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

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

(H20) x .248 = Kilopascals

km

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.88 = IMP

(L) x .22 = IMP

Quarts,

(US

qt) x .833 = IMP

Gallons

(US

(L) x 1.057 = Quarts

(L) x .264 = Gallons

(kPa) x .145 = psi

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

3

=in

pt

qt

gal

qt

gal) x .833 = IMP

gal

TORQUE

Pounds-Force
Pounds-Force

Inches
Feet

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles
Kilometers
Miles
Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

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

LIQUID

WEIGHTS

Diesel

Oil

Fresh

Water
Gasoline
Salt

Water

= 1

= 1

= 1

US

= 1

US

US

gallon = 6.1

US

(in-Ib) x .113 = Newton

(ft-Ib) x 1.356 = Newton

(Kw) x 1.34 = MPH

(MPG) x .354 = Kilometers

(KmlL) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(KmlL) x 2.352 = US

(OF) = (OC X 1.8) + 32

gallon = 7.131bs

gallon = 8.33

Ibs

gallon = 8.56

Ibs

MPG

Ibs

Meters

Meters

Per

Hour

Pe~

MPG

(Nm) x 8.85

(Nm) x .738 = ft-Ib

(KPH) x .621 = MPH

Liter

(Km/L)

Per

Liter

(Km/L)

=in-Ib

Engines,

52

& Generators

SPECIFICATIONS-64A

FOUR

MARINE

ENGINE

Engine

Type

Aspiration
Combustion
Bore & Stroke

Piston
Firing
Direction

Compression

Dimensions -inches
Engine

Weight
Inclination

Generator

Chamber

Displacement

Order

of

Rotation

Ratio

Only

Power

Take

TUNE-UP

Compression
(Limit
between

Valve

Valve

Valve
(engine

Injector
Engine

Pressure

of

difference
cylinders)

liming

Seat

Angle

Clearance

cold)
Pressure

liming

SPECIFICATIONS

Diesel,

.

(mm)

Off

four-cycle,
water-cooled,
mechanism

Naturally
Swirl

type.

3.74

x4.13

182

cubic
1 - 3 -4-2
Clockwise,
21:1

Height:

27.3

Width:

25.5

Length:
678

Ibs

Continuous

Temporary

40

Hp

(Maximum)

vertical

..

aspirated.

inches

inches

when

viewed

inches

inches

38.8

inches

(307

kgs).

15°

25°

(not

four-cylinder,

(95 x 105

(2.98

(647.7

SPECIFICATIONS

427

psi

(30

kg/cm2)

47.2

psi

(3.0

kg/cm

Intake

Opens

17"

Intake

Closes

Exhaust
Exhaust

Intake

45°

Exhaust

Intake

0.012

Exhaust

1920 + 71

Static

timed-drop

0.205 ± .005

47"

Opens

Closes

30°

inches

0.012

-0

psi

inches

BTDC
ABDC

51 ° BBDC

13°

inches

(135
valve

in-line

liters)

from

(694.0

(985.8

to

exceed

at

200

2

)

ATDC

(0.3

mm)

(0.3

+ 5 - 0

method

BTOC

fresh

overhead

mm)

the

front.

mm)

mm)

mm)

20

min.)

rpm

mm)

kgf/cm2).

valve

General
Fuel

Injection

Fuel
Fuel

Injection
Nozzle
Fuel

Filter
(on

engine)

Air

cleaner

Airflow
(engine

combustion)

General

Operating
Fresh

Water

Raw

Water

Raw

Water

at

2600

rpm

System

Capacity

(coolant)

General
Oil

Filter

Sump

Capacity

(not

including

Operating
(engine

hot)

Oil

Grade

Pump
liming

COOLING

Temperature

Pump

Pump

Flow

LUBRICATION

filter)

Oil

Pressure

FUEL

SYSTEM

Open

flow,

No.2

diesel

ZEXEL

Model

0°

TOC

(Top

Throttle

type.

Spin-on

type,

Paper

element-cleanable

94.6

cfm

Fresh

water-cooled

controlled
170-190° F

'Centrifugal

Positive

displacement,

belt-driven.

15.0

gpm

discharging

13.0

US

qts

Pressure
Full

flow,

6.5

U.S.

qts

plus

filter/cooler

50 -60

psi

API

Specification

SAE

30,

10W-30,

self

priming-1

oil

(cetane

rating

VE

Distributor

Dead

Center).

full

flow

(2.7

cmm)

.

SYSTEM

block,

with

heat

exchanger.

(77

-88°

type,

metal

impeller,
rubber

(56.7

Ipm)

(measured

into

exhaust

(12.3

liters)

SYSTEM

fed

system.

paper

element,

(6.15

liters)

assembly

(3.5 -4.2

kg/cm

CF

or

15W-40

bleed

point.

of

45

or

higher).

(Diesel

KiKi)

thermostatically-

C)

belt-driven.

impeller,

before

elbow).

spin-on

type.

2

)

CG-4,

Emission
Systems

EXHAUST

Control

EMISSIONS

Indirect

Fuel

SYSTEMS

Injection

Starting

Battery

Capacity

Battery
Starter
Starting

Aid

Battery

Charging

Alternator

Engines & Generators

53

ELECTRICAL

12
400 -600
12

'Glow

51

Volt,

Volt,

plugs,

Amps

SYSTEM

(-)

negative

Cold

reduction

sheathed

ground

Cranking

gear

type

Amps

(CCA)

CONTACT

YOUR

SUGGESTED

WESTERBEKE

'MARINE

DEALER

SPARE

PARTS

ENGINES

EOR.SUGGESTIONS

AND

ADDITIONAL

INFORMATION

WESTERBEKE
ENGINE
AND A GALLON

FUEL

LINE

(OWNER

FILTERS

INSTALLED)

WESTERBEKE also
each packaged in a rugged hinged

Kit "A"
Kit "B"

includes

is

more

KIT

A

DRIVE
OIL

FILTER

FUEL

FILTER

FUEL

SYSTEM

FUEL

PUMP

offers

the basic

extensive

BELTS

HARDWARE

INLET

RECOMMENDS

OIL

(YOUR

OF

two

Spare

toolbox.

spares.

FILTER

BRAND)

PREMIXED

Parts

Kits,

KIT

CARRYING

FOR

AN

OIL

COOLANT.

SPARE

ENOUGH

CHANGE

SPARE

PARTS

KITS

KIT

B

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER
INJECTOR
OVERHAUL
AIR

GLOW

FUEL
FUEL

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PLUG

SYSTEM
PUMP

GASKET

INLET

MOLDED
HOSE

KIT

(INA

CANVAS

CARRYING

KIT

HARDWARE

FILTER

KIT

BAG)

Engines & Generators

54

Engines & Generators

107412D3WMDW