Westerbeke 65A-FOUR, 65B-FOUR Operator's Manual

OPERATORS

-,.

---. ~ -.

--;

-_.-

......

.

MANUAL·

MARINE

- .

.

65A-

DIESEL

--.

-

---

•.

"-~-~~--

FOUR~!AND

-

-----..--=---::..-:-::.--

REVISION 2

JUNE

<

2011

ENGINES

-~ ._-_.------------

-.

~- .. - -

658 -F·OUR

..

- - -

.

'.

WESTERBEKE'

WESTERBEKE

150

JOHN

FAX

1-508

'..,;,.,~

NMMA

CORPORATION'

HANCOCK

884-9688'

..

Member

ROAD,

TAUNTON,

WEBSITE:

-

_.

National

MYLES

STANDISH

MA

www.WESTERBEKECOM

Marine

Manufacturers

INDUSmlAL

02780-7319'

.

Association

PARK

TEL.

1-508·823-7677

---

A

WARNING

Exhaust

colorless

unconsciousness

exposure

-Dizziness

-Nausea

-Headache

-

IF
GET
seek
until

gasses

gas.
can

Weakness

YOU

OUT

and

OR

ANYONE

INTO
medical
it

has

been

contain

Carbon

and

include:

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

A

WESTERBEKE

bulkhead

WESTERBEKE

CARBON

living/sleeping
Theyare
obtainable

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY.
down

repaired.

WARNING

an

and

of

Carbon

in

Temples.

7Ivitching

to

Think

ANY

OF

THESE

If

the

unit

and

DECAL

and

should

near

your

also

recommends

MONOXIDE

quarters

inexpensive

at

your

odorless

symptoms

is

engine
DETECTORS

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

do

not

restart

provided

and

be

fixed

or

generator.

of

your

easily

marine

by

installing
in
vessel.

store.

to

the

a

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

gasoline

of

State

its

birth

WARNING

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure
precautions.
take the

Know

necessary

personnel, and your

The

following

the

American

PREVENT

A

WARNING:

while

power.

•

Do
enclosures

• Shut off electrical power
equipment.

•

Use
equipment.

•

Make

(particularly

•

Remove
electrical

•

Do
circuits,
transfer
result if

• Electrical shock
tor.

.

PREVENT

A

WARNING:

exhaust

very

•

Always

recovery

A

•

In

case

before

safety

Boat and

ELECTRIC

engine

is

Lethal

voltage

not

operate

and

insulated

sure your

shoes)

wristwatch

equipment.

not

connect

except through a ship-to-shore
switch.
this

procedure

Discharge

BURNS -HOT

system

hot!

check the

tank.

WARNING:

of

an

touching

carefully.

to

follow

when

dangerous

precautions

machinery.

instructions

Yacht

SHOCK

Do

not

running,

is

this

machinery

covers

mats

whenever

clothiug

when

and

utility
Damage

results

capacitor

Do

not

components. A running

engine

Steam

engine

overheat,

the

engine

Most

fundamental

to

protect

are

Council

touch

AC

electrical

or

when

connected

present

in

shore

is

place.
before

aud

handling

all

jewelry

power

to

vessels

not

from

by

shorting

at

without

accessing

working

skin

followed.
haudling a

ENGINE

touch

hot

coolant

can

cause

allow the

or

checking

accidents
rules

conditions

yourself,

in

compliance

(ABYC)

connections

these

connections!

electrical

electrical

on

electrical

are dry,

engine

electrical

when

to

vessels

double

AC

generator

charged

terminals

parts

not

working

engine

level

at

the

injury

or

engine

the

are

and

exist

and

your

with

standards.

to

shore

damp

equipment.

on

AC

throw

may

capaci-

together.

or

gets

coolant

death!

to

cool

coolant.

PREVENT

A

• Prevent
sparks
pump,
vapors.
removing

•

Do

arrester

death.

•

Do
Backfire

•

Do
the fuel
engine/generator clean

chances of

•

Be

PREVENT

A

injury

• Follow
hatches

•

.•

• Shut off

•

•

•

• Make sure a

BURNS -FIRE

WARNING:

flash

to

occur

or

other

Use a suitable

the

not

operate

removed.

not

operate

can

not

smoke

system.

fire.

aware -

BURNS

WARNING:

or

death!

re-fueling

closed

after

fueling. Check
running the
before starling

All

fuel
when
ventilated
and out of

Do

not

the fuel
spill.
sources
ing.
fuel

Do

not

Be

sure

Be

certain

free of

properiy
Extinguishers
for

all

blower.

vapors

handling

area

the

fill

the

the

system.

DO

NOT

of

fire

Ensure

proper

system.

alter

all

fuel

fuel

leaks.

maintained.

applications

Fire

can

fires.

Do

not

near

the

potential

container

fuel

line,

with

a Coast

Backfire

with

the

cause

severe

or

permit

Keep

the

Wipe

up

diesel

fuel

-'

EXPLOSION

Explosions

safety

when

fueling.

below

Run

your

engine.

are

highly

aud

storing

away

from

reach

of

fuel

tank(s)

fuel

service
Take

care in

allow

any

near

the
ventilation

or

modify

supp,lies

line

fittings

fire

extinguisher

Be

rated

ABC

encountered

cause

injury

smoke

carburetor,

sources

carburetor,

air

flames

and

will

children.

valve

fuel

the

of

to

Guard

can

cause

cleaner/silencer

injury

or

or

compartment

free

of

all

spilled

bum.

from

fuel

instructions.

Open

for

fumes/vapor

the

blower

explosive.

fuels.

spark-producing

while

at

the

catching

smoking,

system

exists

fuel

system.

have a

positive

are

adequately

is

installed nearby

familiar

by

the

in

or

or

permit
fuel line,
spilled

catch

or

fuel

Approved

severe

death.

sparks

and the

debris

fuel

aud engine

vapors

Keep

and

ventilate

for four

Use

Store

fuel in a

the

engine

engine

any

open

or

engine
when

with

its

NFPA

are

this

environment.

death!

flames

filter,

fuel or

all

fuel

filters.

flame

injury

removed.

to

occur

to

minimize

can

the

before

minutes

extreme

equipment

is

running.

when

fuel

flames,

when

servicing

shutoff

tightened

proper

appropriate

or
fuel

fuel

when

or

near

oil.

cause

vessels

cabin

care

well-

servicing

that

might

or

other

servic-

valve.

and
use.

the

the

and

is

~

WESTERBEKE

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

Disconnect
generator.
it

last.

•

Make
starting.

•

Make
installed

BATTERY

A

WARNING:

or

death!

•

Do

not
being
highly
arcing
equipment
ing

•

Never

tive
not
together.
Ventilate
accumulation
disturb
is

being

•

Avoid
bums

wristwatch,
the

•

Always
the

and

BATTERY

A

WARNING:

severe

•

When
level,

tion.

If

it

with
inadvertently

STARTING

the

Remove

certain

all

certain

all

before

EXPLOSION

smoke

serviced.

explosive

or

by

lit

in

the

servicing.

connect

(+) connection tenninal

test

the

battery

Sparks

any

compartment

of

the

battery

charged.

contacting

or

sparks

rings,

battery.

tum

the

battery

connections.

reconnect it

ACID

injury

or

servicing

wear rubber

Batteries

comes

in

water.

Acid

Accidental

battery

cables

the

negative

personnel

covers.

guards,

starting

Battery

or

Lead
tobacco

the

the

explosion

allow

an

acid

gas,

which

products.

vicinity

negative

condition

could

ignite

explosive

charger

the

tenninals

that

could

and

any

battery
last

whenservicing

Sulfuric

batteries

to

charger
Remove

acid

death!

the

battery

gloves, a rubber

contain

contact

when

sulfuric

with

may

splash

removing

starting

are

open

connections

cause ~ explosion.

can

cause

before

servicing

lead

first

and

clear

of

the

engine

and

hatches

engine.

can

flame

emit

can

be

ignited

Shut off

prevent

electrical

(-)

battery

of

the

starter

by

shorting

batt~l{'

contalOmg

gases.

To

with

other

Jewelry

off before disconnecting

the

the

in

batteries

or

checking

apron,

acid

which

your

skin,

on

the

electrolyte

are

cause

near

the

hydrogen,

by

all

cable to

solenoid.

the

gases

o~

battenes

avoid

sparks,

while

tools,

etc.,

before

negative lead

battery.

can

the

electrolyte

and

is

wash

it

skin

or

into

caps.

injury

the

engine!

reconnect

before

re-

injury

battery

a

elect;ical
eleclncal
arclOg

dur-

the

posi-

Do

terminals

fuel

vapors.

to

prevent

do

not

the

battery

to

prevent

Remo~e

handllOg

first

cause

eye

protec-

destructive.

off

at

once

the

eyes

•

TOXIC

•

•

EXHAUST

A

WARNING:

Ensure
discharged

regularly
water-injected

Be

sure

Run

blowers

• Don't
equipped
detector
builder

• For

additional

(educational

A

WARNING:

odorless
nausea

•

Do

not
fumes
Exhaust sulfur
resulting

•

Do

not
through
exhaust
enter
flow

•

Although
exhaust

gas

is
symptoms
poisoning

Vomiting

Dizziness

Headache

Nausea

AVOID

A

WARNING:

or

death!

•

Do

arises

ing

ing

GASES

Carbon

that

the

exhaust

from

the

for

leaks

elbow

the

unit

and

when

run

the

generator

with a functioning

that

complies

or

dealer

for

information

information

Carbon

gas.

Inhalation

or

death!

use

copper

can

rapidly

causes

in

exhaust/water

install

exhaust
portholes,
discharge

the

exhaust

of

exhaust.

diesel

fumes

from

present

in

or

signs

are:

MOVING

not

in

adjustments,

parts

service

which

and

PARTS

Rotating

the

it

hot

monoxide

system

engine.

and

make

is

securely

its

surroundings

running

set

with

installation

on

monoxide

produces

tubing

in

destroy

copper

rapid

leakage.

outle,t

vents,

or

outlet

is

discharge

Avoid

overloading

engine

exhaust

gasoline

diesel

exhaust

of

carbon

Inability
Throbbing
Muscular
Wealrness

parts

engine

is

absolutely

use extreme

exhaust

(CO)

is a deadly

is

adequate

Check

sure

the

attached.

the

generator

or

engine

marine

ABYCA-24.

of

refer

to

ABYC

Carbon

{CO}

"u-like

diesel

exhaust

tubing

deterioration

where

air

conditione~s.

near

the

outlet

and

gases

engines,

fume~.

monmade

to

can

while

it

necessary

care

system

components.

to

expel

the

exhaust system

exhaust

are

unless

carbon

approved

Monoxide).

manifold!

well

ventilated.

set

or

engine.

the boat

monoxide

Consult your boat

detectors.

T-22

is

an

Invisible

symptoms,

systems.

in

exhaust

of

copper

exhaust
waterline,

in

twitching

and

is

to

can

If

water

close

or

restrict

the

craft.

are

not

as

carbon

monoxide

S?me

o~

mhalatlOn

think coherently

temples

sleepiness

cause

injury

running.

avoid

If a situation

to

make

touching

gas!

gases

systems.

be

drawn

the

engine

toxic

the

operat-

is

Diesel
tublOg

could

the

as

or

mov~

~

WESTERBEKE

Engines & Generators

ii

•

Do

not

wear

loose

equipment;

jackets,

could

•

Make

Keep
places

•

Do

not

the

engine

•

Stay
when
be

caught

HAZARDOUS

A

WARNING:

tie

shirts,

be

caught

sure

all

protective

at

all

times.

check

is

clear of

the

engine

in

NOISE

sleeves,

attaching

fluid

operating.
the

these

loss!

•

Never

operate

an

•

Do

not

run

an

engine

removed.

•

Do

not

run

engines

open.

A

WARNING:

mentally

or

physically

clothing

back

long

rings,

in

moving

shields

levels

drive

shaft

is

running;

rotating

High

noise

engine

with

for

long

Do

not

work

Incapacitated

or

jewelry

hair

and

necklaces

parts.

hardware

and

guards

or

the

and

hair

parts.

levels

without

the

air

periods

on

SAFETY

when

avoid

wearing

or

bracelets

is

properly

in

their

respective

drive

belt's

the

Iransruission

and

clothing

can

cause

its

muffler

intake

(silencer)

with

their

machinery

by

fatigue!

when

servicing

loose

tightened.

tension

coupling

can

easily

hearing

installed.

enclosures

you

INSTRUCTIONS.

that

while

are

ABYC,
INSTALLING

Read
for
tions

ABYC

"Safety
Order

NFPA
"Fire

Order

USCG

"USCG
Order

NFPA

the

following

safety

codes

when

installing

(American

Standards

from:

ABYC
3069

Solomon's

Edgewater,

(National

Protection

from:

NFPA

II

Tracy

Drive

Avon

Industrial

Avon,

MA

(United

33CFR183"

from:

U.S.

Government

Washington,

AND

OIESEL

and

for

MD

Fire

Standard

02322

States

D.C.

USCG

ENGINES

ABYC,

standards.

your

engine.

Boat

and

Small

Island

Rd.

21037

Protection

for

Park

Coast

Printing

20404

PUBLICATIONS

NFPA

and

USCG

Follow

their

Yacht

Council)

Craft"

Association)

Motor

Craft"

Guard)

Office

FOR

publications

recommenda-

OPERATORS

Many

of

in

your

notes

to
carefully,
procedures.

ENGINE

Preparations

ough

exaruination

(ABYC)
sources

Sections

H-2
P-I Exhaust
P-4
E-9

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintaln

Manual

critical

INSTALLATIONS

to

.install

standards.

including

of

the

the

ABYC

Ventilation

Inboard
DC

Electrical

must

(FCR).

safety

your

equipment,

an

of

the

These

USCG

standards

systems

engines

comply

tips

and

along

with

infonnation.

engine

should

American

standards

and

the

of particular

systems

with

warnings

other

Read

and

begin

Boat

are a combination

NFPA.

the

Federal

cautions

your

follow

and

Yacht

are

manual

all

with a thor-

interest

Code

repeated

and

safety

Council's

of

are:

of

~

WESTERBEKE

Engines & Generators

iii

When

installing

attention

WESTERBEKE

be

paid

to

the

following

·

INSTALLATION

engines

information:

and

generators

it

is

important

that

strict

CODES

Strict
when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON·BREAK

For

installations

or

will

be

break

in

minimum

the

exhaust

raw

water

If

you

have

to

the

vessel's

siphon·break.

NOTE:

A
operation.
engine

damage.

EXHAUST

The

exhaust

prevent

of

the

vessels

where

below

the

the

raw

water

of

20"

above

manifold

damage

siphon-break

Failure

any

doubt

waterline

Consult

to

to

SYSTEM

bose

must

water

from
hull.

vessel's

properly

entering

ABYC

and

generators

the

exhaust

waterline,

supply

the

vessel's

injection

the

engine

about

the

under

requires

the

siphon-break

be

certified

the

guidelines,

manifold/water

hose

to

waterline.

port

and

position

the

vessel's

periodic

maintain a siphon-break

for

exhaust

in a marine

provisions

the

exhaust

is

at

or

possible

of

the

various

inspection

manufacturer

marine

under

and

safety

environment.

injected

must

elbow.

Failure

below

the

flooding

water-injected

operating

and

use.

The

any

sea

codes

must

be

exhaust

be

made

This

to

use

load

of

the

cleaning

can·

for

system

conditions

elbow

to install a

hose

must

a siphon.breakwhen

waterline

boat.

exhaust

conditions,

to

ensure

result

in

proper

·maintenance.

must

and

complied

wl7l

elbow

catastrophic

be

at

with

is

close

siphon-

be

looped

result

relative

install

a

proper

designed

any

angle

in

to

a

to

~V~ILABLE

YOUR

OE~LER

FROM

WESTERBEKE

A

detailed
engine
available

Marine

and

to

Installation

generators

download

is

from

'"tIY'

Manual

supplied

our

covering

with

each

website

unit. A pdf

at

www.westerbelre.com.

WESTERBEKE

Engines & Generators

iv

gasoline

copy

and

diesel,

is

TABLE

OF

CONTENTS

Parts

Identification

Introduction

Serial

Ordering Parts ............................................................ ..4

Control
Control
Diesel

Coolant Recovery

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

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

Panel
Panel

Fuel,

Engine

Preparations

Pre-start Inspection ....................................................... 8

Starting/Stopping
Warning

Lights,

Maintenance

Cooling

Fuel

Engine

Remote

W'
Wiring

Engine

Circuit

Raw

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

Draining the

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

Fresh

Water Circuit ....................................................

Changing Coolan!... ....................................................

Raw

Water

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

Water

Heater ...............................................................

System

Fuel
Fuel

Oil

iO"

n

ng

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

Filter ...................................................................

Water Separator ..................................................

L~bricating

Change .................................................................

Oil

Filter

lagram

Schematic

Adjustments

Fuel

Injectors .........................................................

Glow

Plugs .................................................................

Valve

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

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

Testing

Engine Compression ..................................................

Oil Pressure ...................................................

(Illustrations)

(Admiral)
(Captain)

for

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

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

Oil

and

Tank

................................................ 7

I.nitial

Start...

Procedure

Alarms & Circuit

Schedule

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

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

Engine

Coolant

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

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

Breaker

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

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

Raw

Water

System ................................

Pump

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

Oil

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

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

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

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

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

2

.3

5

6

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

7

8

9

10

11

13
13

13

14
15
15

16
16
17

18
18

18

19
19

20

21

22

23

~

....

23
24

25
26
26
26

Tachometer

Engine
Control
Alternator

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

Testing

Checking/Servicing Battery ......................................

Battery Care ..............................................................

Dual

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

High
Starter

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

ZF

Transmissions

Change

Specifications .............................................................

Control Cables ...........................................................

Transmission Cooler ...................................................

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

ZF

Transmissions

Change the Fluid .......................................................

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

Velvet

Change

Troubleshooting ..•......................................................

Oil

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Specifications
La

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Troubleshooting

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Output
Output

Alternators
Alternators

Motor

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

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

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

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

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

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the Fluid ........................................................

(H8W

Models)

Drive

Transmissions

the Fluid .......................................................

Coolers

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~

WESTERBEKE

Engines & Generators

1

INTAKE

'''",lItULU,

PARTS

IDENTIFICATION

CRANK

VALVE

CASE

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FUEL

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AND

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OIL

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EXCHANGER~.

EXHAUST

DC

ALTERINATOR

LEFT
OIL
(OPTIONAL)

LEFT

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2

This

WESTERBEKE

WESTERBEKE'S

technology.
dependable
Thank

In

order

important

manual

manual

throughout.

your
This

be

available
planning
your
Installation

Customer

We

take

performance

you

for

selecting

to

get the

that

you

is designed

carefully

Should

nearest

WESTERBEKE

is

your

Operators
from

to

install

WES1ERBEKE

Manual.

Identification

,WESTERBEKE

''''''"

Customer
WESTERBEKE
MAIN
HOMETOWN,
Model
Expires

,

Identification

STREET

INTRODUCTION

Engine

is

a product of

long

years

of

experience

great

pride

in

the

of

our

engines

WESTERBEKE.

full

use

and

benefit

operate

and

your

this

and

maintain it

to

help

you

do

observe

your

all

engine

dealer

Manual.

WESTERBEKE

equipment

dealer

A Service

for

this.

the

safety

require

for assistance.

contact

WESTERBEKE'S

Card

Engines & Generators

OWNER

USA

Ser.#

and

superior

and

generators.

from

your

correctly.

Please

precautions

servicing,

Manual

dealer.

yourself,

advanced

durability

engine,

read

contact

wili

If

you

contact

This
this

are

and

it

also

WES1ERBEKE
span

between
software
WES1ERBEKE
provided
WES1ERBEKE or

is

be

the
but
WESTERBEKE
to
product software

and

with

relied

upon
respective
is

imperative that appropriate

determine

NOTES,

As

this

manual
maintenance
engine,
CAUTIONS,

critical infonnation

NOTE:

An operating

A

CAUTION:

can

result

A

WARNING:

can

result

customers

printings

the

WESTERBEKE

exclusively

product.

the

CAUTIONS

schedules,

and

of
unavoidable
manuals.

other

It

or

the

supplier in

accuracy

being

consulted

AND

takes

you

and

WARNINGS.

procedure

Procedures,

In

the

damage

Procedures,

in

personal

injury

should

also

WES1ERBEKE

existence

In

summation,

products,

suppliers,

as

not

and

must

the

definitive

only

makes

representatives

question

currentness

by

the

WARNINGS

through the

troubleshooting

wili

or

operating

be

highlighted

An

explanation

essential

which

if

destruction

which

if

Dr

loss

Df

keep

in

product

of earlier

product

whether

not

and

authority

good

sense

be consulted

of

the

customer.

of

to

note.

not

strictly

of

your

not

properly

life.

mind

the time

software
from

carmot

on

of

procedures,

your

marine

by

NOTES,

follows:

observed,

engine.

fDIIDwed,

WARRANTY

Your

WES1ERBEKE

folder.

registering

card
Warranty
writing
number

PRODUCT

Product

brochures
WES1ERBEKE

PROCEDURES

If,

you

have

your

Registry form,

with

model

and

commission

SOFTWARE

software,

and

catalogs),

Warranty

not

received

warranty

please

information,

date.

(tech

data,

provided

are

not

within

is

included

a customer identification

60

days

contact

including

parts

lists,

from

WES1ERBEKE's

in a separate

after

submitting

the

factory

the

manuals,
sources

unit's

other

the

in

serial

than

control.

PROTECTING

Care

at

the
resulted
of

hours

not

control

the

marmer

This

is

up

NOTE:

Six important steps

• Proper engine installation.

• An

efficient,

anti-syphon

•

Changiug

• Proper
mainteuance

•

Use

clean,

•

Winterize

RECOMMISSIONING

YOUR

INVESTMENT

factory

during

assembly

in a WESTERBEKE

of

dependable
how

in

which

to

the

break

the

maintenance

filtered

your

service.

or

where

the

the unit

buyer/owner-operator.

to

well-designed exhaust

to

prevent

engine

oil

of

all

schedule

diesel fuel

engine

in

according

section in

and

engine

capable

However,

engine

is

is

operated

ensure a long

water

every

250

engine

components

this

manual.

to

this

thorough

of

many

the

manufacturer can-

installed

system

from

operating

the

in

and

serviced in the

engine/generator

that

entering

hours.

according

LAY-UP

manual.

testing have

thousands

the

vessel

field.

includes

AND

the

an

engine.

to

or

life.

the

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WESTERBEKE

Engines & Generators

3

INTRODUCTION

SERIAL

The engine's model
the namepiate mounted

jacketed exhaust

stamped
the
the nameplate below.

Fill

UNDERSTANDING

The

since
are
same
engine
connecting

Therefore,

same
most
maintenance
Fuel
time

contaminations

also

brand

specifically

The

however,

carburetor

component -the

function

NUMBER

in

the engine block on the right rear side just

side

oil fill. Enter

in

the

information

LOCATION

number

on

manifold.

this

Use

for your

THE

diesel

engine

closely

the

mechanism

arranged

general

has

to a great

preventive

important

and

lubricating

periods

essential.

of high

diesel

in

and

of

above a closed

the

rods

of
specified

for

eugine

its

both.

is

essentially the

type

as

that

same

types

and

lubricating system.

extent,

maintenance

factors

are proper

the

fuel,

filler

and

(water,

sediment, etc.) in

Another

detergent

ignition

important

diesel

engines.

does

differ from

method

of handling
systems are

fuel

injection pump -

diesel lubrication

and serial number

the side

The engine's serial number

information

it

DIESEL

resembles

of a gasoline

of valves,

lubricating

elements

frequent

of

the

on

for a quick reference when needed.

referanee.

ENGINE

the

same.

crankcase.

a diesel

as

The
engine,

camshaft,

engine

a gasoline

ventilation

and
must
checking

factor

the

gasoline

and

replaced

are

located

engine's water

the illustration of

gasoline

cooling

be

is

firing
which

The

crankshaft

and
pistons,

requires

engine.

and

replaced

for

the

fuel

the

use

oil

designed

of

by

performs

engine,

cylinders

the

the

The

proper

systems.

at

system

of the

engine,

fuel.

The

a single

above

is
diesel

is

the

the

is

same

the

on

ORDERING

Whenever
engine
appear
martifold.
may

properly
complete
needed
WESTERBEKE
parts

original

SPARES

Certain

WESTERBEKE

will

assist

the

SPARE

accessories,

PARTS

replacement

model

number

on

the silver
You

must

identify

part

description

(see

the separately

are

frequently

equipment.

AND

spares

will

you

in

PARTS

see WESTERBEKE'S ACCESSORIES brochure.

parts

are

needed,

and

engine

serial

and

black

name

plate

provide

packaged

not

your

made

us

with

engine.

and

part number

furnished

parts

to

the

this

In

Parts

because will

same

ACCESSORIES

be

needed

to

support

engine.

Your

local WES1ERBEKE dealer

preparing

page

in

an

inventory

this

manual.

always

provide the

number

addition,

For

as

located on the

information so

include a

for

each part

List). Insist

fit

or generic

specifications

and

maintain

of

spare

engine

they

parts.

we

upon

as

your

See

~

WESTERBEKE

Engines & Generators

4

DESCRIPTION

This

manually-operated

KEY

switch

and

RPM

meter

which

measures

in

1/10

hours.

The panel
AWRE
Fahrenheit,

engine's
control

tem's

switch
is
pushbuttons,

RPM
TERS
PER
ENGINE
RECALIBRATED
ACCURACY
REAR

gauge

an

oil

pressure

circuit

VOLTAGE

voltage.

in.

operation.

is

turned

All

one

GAUGE:

REGIS·

REVOLUTIONS

MINUTE

OFTHE

AND

CAN

BE

FOR

FROM

THE

THE

PANEl.

OF

which

OIL

PRESSURE

gauges

on

and

The

for

control
gauge
the

engine's running

also

indicates

in

pounds

gauge

are illuminated

remain

panel

also

PREHEAT

WATER
GRADUATED
ILLUMINATED
TURNED
TEMPERATURE

panel

is

with

an

ELAPSED

includes

water

gauge

a WAlER

temperature

which

per square

which

measures

illuminated

contains

two

and

one

TEMPERATURE

IN

DEGREES

WHILE

ON.

THE

IS

ADMIRAL

equipped

with

CONTROL

a

TIME

time

in

hours

and

TEMPER-

in

degrees

inch,

when

while

measures

and a DC

the

the

the

the

sys-

key

engine

rubber-booted

for

START.

GAUGE:

THIS

GAUGE

FAHRENHEIT

THE

KEY

ENGINE·S

NORMAL

170"

-190"

SWITCH

F tn"-R/'"r.'.

IS

AND

IS

IS

OPERATING

PANEL

When

the

engine

the

water

temperature
temperature
power

was

when

the

key
will

once

again
elecmcal

A
Admiral
necting
elecmcal
the
be
running.
on
engine's

separate

Panel.

the

buzzer

audible

The

arid

should

oil

power

harness.

is

shut

gauge

reading

indicated

turned off. The

switch

is

turned

register the engine's

is

restored

alarm

buzzer

with

The

installer

buzzer

to

the

The

installer

in a

location

to

the

·buzzer
silence

pressure

where

operator

will

when

rises

OIL
ATED
ILLUMINATED
ON.
PRESSURE
(2.1 -4.2

down

with

the

key

switch turned

will

oil

continue

by

the

pressure

to

gauge

before elecmcal

gauge

off. The temperature gauge

true

temperature when

to

the

gauge.

harness

is

four-pin

should

sound

the

above

PRESSURE

IN

POUNDS

THE

ENGINE·S

is

responsible

connection

is

also

responsible

it will

be

it

sound

when

the

engine

has

15

psi

GAUGE:

PER

WHILE

THE

NORMAL

RANGES

kg/em').

BETWEEN

supplied

for

on

dry

and

while

ignition

started

(1.1 kg/em').

THIS

GAUGE

SQUARE

KEY

OPERATING

register the

will

fall

to

with

every

elecmcally

the

engine's

for

installing

where

it

the

engine

key

is

and

t\je

IS

GRADU·

INCH

(PSI)

SWITCH
30 -60

AND

IS

TURNED

OIL

psi

.

off,

last

zero

con-

will

is

turned

IS

HDURMETER:
REGISTERS

TIME,
USED
THE

MAINTENANCE

SCHEDULE.

START
STARTER'S
THIS
UNLESS
AT

THE

~m---

ELAPSED

AND

SHOULD

AS A GUIDE

BUTTON:

SOLENOID

BUTTON

WILL

THE

PREHEAT

SAME

TIME.

BE

FOR

WHEN

WHICH

NOT

PRESSED,

CRANKS

OPERATE

BUTTON

IS

__

ENERGIZES

ELECTRICALLY
PRESSED

THE

THE

ENGINE.

AND

HELD

~

~

~

:

"

.-

••

"

AUTOMATIC
COOLANT

SUPPLIED
REACHES
ALARM

OIL
LOCATED
THE

FALL
ING
SIGNAl.

ALARM

TEMPERATURE

WITH

210' F (99'C),

WHICH

PRESSURE

OFFTHE

ENGINE'S

TO

5 -10

THE

ALARM.

~

SYSTEM

THE

INSTRUMENT

WILL

EMIT

ALARM:

ErfGINE'S

OIL

PRESSURE.

psi

(0.4

-0.7

IN

THIS

ALARM:

AN

THIS

SWITCH

A

CONTINUOUS

AN

OIL

PRESSURE

OIL

GALLERY.

SHOULD

kg/em'),

EVENT,

THE

ALARM

PANEl.

WILL

THE

THE

ALARM

BUZZER

IF

THE

ENGINE'S

CLOSE

SIGNAl.
ALARM

THIS

SWITCH

ENGINE'S

SWITCH

WILL

VOLTMETER:

INDICATES

BAm~Y

SHOULD

SOUNDING

SWITCH

WILL

EMIT

THE

IS

SHOW

HAS

BEEN

COOLANT

IS

MONITORS

OIL

PRESSURE

CLOSE

A

PULSATING

AMDUNTTHE

BEING

CHARGED.

13VTD

THE

SOUND·

14V.

Engine~

&

Generators

5

DESCRIPTION

This

manually-operated

KEY

switch,

an

RPM

tons,

an

INSTRUMENT

lamps,

one

for

ALTERNATOR

OIL

PRESSURE,

TEMPERATURE.

RPM

GAUGE:

MINUTE

REAR

Of

REGISTERS

Of

THE

PER
RECALIBRATED
THE

and

THE

ENGINE

fOR

ACCURACY

REVOLUTIONS

control

gauge,

PREHEAT

TEST button

one

for

high

AND

CAN

BE

fROM

CAPTAIN

panel

is

equipped

and

START

and

three

DISCHARGE,

ENGINE

with

a

but-

indicator

one

for

low

COOLANT

CONTROL

The

PANEL

panel

also
PRESSURE
RPM

gauge

is

and

remains

ALARM:

THE

5 -10

(99'C).

THE

ALARM

IS
REACHES

ALARM

psi

SIGNAL

IN

IN

NORMAL.

BELOW

PULSATING

TEMPERATURE

210'f

NOTE:

SOUNDING
PRESSURE

includes

or

high

COOLANT

illuminated

illuminated

WILL

SOUND

(0.4 -0.7

kg/em').

THE

ALARM

THE

fRESHWATER

THIS

EVENT,

WILL

SOUND
ONCE

15

psi

(1.1

an

while

THE

WHEN

THE

kg/em'),

alarm

buzzer.
TEMPERATURE.

when

the

the

engine

If

THE

ENGINE'S

IN

THIS

ALSO

COOLING

WILL

THE

ENGINE

STARTS

THE

EVENT,

SOUND

KEY

ALARM

WILL

ALARM

for

low

OIL

KEY

switch

is

in

operation.

OIL

PRESSURE

THE

ALARM

If

THE

CIRCUIT

EMIT

SWITCH

COOLANT

RISES

TO

A

CONTINUOUS

IS

TURNED

AND

THE

ENGINE'S

WILL

SILENCE

TEST

BUTTON:

PRESSED,

ALTERNATOR,

PRESSURE,
COOLANTTEMPERA­TURE

CONTROL

CUITS.

WHEN

THE

ALTERNATOR,

OIL

PRESSURE,

THE

WATER

TURE

INOICATOR

LIGHTS

ILLUMINATE
ADDITION
ING

THE

ALARM

BUZZER,

The

is

turned

fALLS

WILL

EMIT

SIGNAL.

ON.

OIL

WHEN

TESTS

THE

THE

AND

THE

CIR-

PRESSED,

AND

TEMPERA·

TO

SOUND·

oil

A

THIS

OIL

THE

IN

START

BUTTON:

STARTER'S

BUTTON
PREHEAT

TIME.

SOLENOID

WILL

BUTTON

WATER
ALARM

WHEN

NOT

OPERATE

IS

WHICH

PRESSED

TEMPERIITUFIE

LIGHT

PRESSED,

/

ENERGIZES

CRANKS

THE

ELECTRICALLY

AND

HELD

THE

ENGINE,

THIS

UNLESS

ATTHE

THE

SAME

Engines & Generators

~---

'PR'FHFI'T

R11TTO,N'

ALTERNATOR'S
SOLENOID
GLOW
SURE
GIZES

ON

PLUGS,

ALARM

THE

START

THE

AND

SWITCH.

WHEN

EXCITER,

THE

INJECTION

BYPASSES

IN

BUTTON,

.,,"

SWITCH:
POWER
INSTRUMENT

CLUSTER.

PRESSED,

ADDITION,

fUEL

LIfT

PUMP,

THE

ENGINE'S

ENERGIZES

THIS

ONLYTO

PUMP,

ANO

THE

BUTTON

PROVIDES

THE

PANEL

THE

THE

FUEL

ENGINE'S

OIL

PRES-

ENER-

6

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

Use a

SAE J
diesel

Care

Use

in
dirt
ondary
important
can be
improper
the
following practice

Purchase a
to
recommended
Diesel
into

used.

Install
filter/water separator
The

such

ENGINE

Use a heavy
CG-4,
initial
filter
SCHEDULE
not

synthetic

using

in
manual

NOTE:

statements

SAE

For

FUEL

diesel

fuel

that

meets

313

and

has a Cetane

fuel

according

Of

The

only

clean

your

engines

particles

tank

combat

the

Raycor

which

filters

to

buy

rendered

storage

for

your engine's

well-known

BACTERIAL

Kleen + Centane

diesel

and

regularly

500

filters. A 10

to

Fuel

Supply

diesel

fuel!

fuel

injection

might

can

damage

clean

fuel,

unsatisfactory

facilities.

is

advisable:

such

as

Bio-

fuel

when

service a good,

between

MA

or

micron

ASTM

brand

growth

Boost

an

230

filter

OIL

duty

diesel

oil

CH-4

or

CIA.

Change

50

hours

of

break-in

change

intervals

approve

the

all

or

oils

are

conventional

MAINTENANCE SCHEDULE

and

not

The

information

regarding

OIL

VISCOSITY

temperature

as

in

this

manual.

disapprove

used,

oil.

be

extended

synthetic

ranges:

specified

engine break-in
Oil

above

GRADE

the

requirements

rating

of

#45

or

D975

The

clearance

pump

pass

through

these

finely

and

keep

by

To

ensure

daily

use

of

fuel.
in

Bar

and

to

help

Ultra

the

RMAM

element

with

an

the

operation.Then

Westerbeke

the

use of

change

if synthetic

supersedes all previous

oil.

SAE

15W

of

is

very

critical;

the

primary

machined

it

clean.

careless

Low

fuel

engine

handling

that

the

is

clean

and

The

use

the

fuel

tank

an

additive

restore

Sulfur diesel

visual-type

tank

and

are

good examples

is

recommended.

API

classification of

oil

follow

in

the

MAINTENANCE

Corporation

synthetic

must

intervals

section

oils

-40

or

of

No.

higher

grade

the

components

invisible
and

parts.

The

best

or

fuel

going

pure,

of additives

is

such

lubricity

fuel

the

engine.

and

filter after

the

oils. If

be

performed

must

be

of

this

are

used.

SAE

IOW-40.

2-D

It

the

as

is

oil

as

of

sec-

is

fuel

into

back

being

of

CF,

and

does

listed

an

ENGINE

WESTERBEKE
and
chemicals that

The antifreeze
run

the engine
cooling circuit
quality
Additives
balanced,

The distilled
being poured

NOTE:

antifreeze that

PURCHASING

Rather
recommends
when
There

(green)
but
flush

Premixed antifreeze for DIESEL Engines:
Specification #ASTM

COOLANT

50%

distilled

at

proper

temperatures

to

the

antifreeze

(SCAs)

crucial

water

into

Look for

than

preparing

buying

adding

coolant

are

two

and

Propylene

do

not

mix

the

engine

recommends

water.

can

corrode

performs

coolant,

from

rust

that

contains

that

to

long

and

the

cooling

the

new

is

now

available.

a mixture of

Distilled

double

and

keep

term

antifreeze

environmentallyjriendly long lasting

water

internal

duty.

by

transferring

and

lubricates

corrosion.

Supplemental Cooling

the

antifreeze

protection.

circuit.

ANTIFREEZE

the

mixture,

the

premixed

the

common

the

two

thoroughly.

mixture

types

Glycol

and

D53456.

will

of antifreeze, Ethylene Glycol

(red/pnrple), either can be used

if changing

is

free

engine

It

allows

and

Look

should

be

WESTERBEKE

antifreeze

always

from

MAINTENANCE

Change
number·of
protect

COOLANT

The coolant

contraction of
without
provided
water coolant conversion kit and must
operating

the

engine coolant

operating

and

lubricate

hours
the

RECOVERY

recovery

the

engines

introducing

with

the

air

fresh

water cooled models

engine.

every
as

the

engine

TANK

tank

allows

coolant during

into

the

five

chemical

have

a limited

for the

system.

years

expansion

This

be

50%

antifreeze

from

the

surfaces.

the engine

heat

away

from

protects

chemically

premixed before

regardless

additives

engine
and

installed

the

for a good

so

that

so

be

correct.

one

to

another,

that

life.

and

operation

recovery

with

the
before

that

of the

tank
fresh

to

is

RECOMMENDED RPM RANGES

[die:

750

- 1000

rpm
Cruise: 2000 • 2400
Max:

2550 • 2600

The

propeller used must allow the engine to reach
at

full open throttle underway

rpm
the rpm there. This will ensure that
properly loading the engine.

rpm

rpm

in

forward gear and hold

the

propeller used

its

rated

is

"'IN"

WESTERBEKE

Engines & Generators

7

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before
prolonged

o

Check
at

o

Thm
examine
contaminants.

o

Check

o

Check
and

(+)

the
stud

o

Check

and

INSPECTION

starting

your

layoff,
the

engine

the

high

mark

on

the

the

the

transmission

the

DC

battery

cable

battery

cable

negative

(this

location

the

coolant

at

the

manifold.

engine

check

on

fuel

supply,

fuel

filter/water

electrical

connections.

is

(-)

cable

for

the

following

oil

level.

the

dipstick.

then

fluid

system.

connected

is

connected

is

tagged).

level

in

the

first

Add

oil

check

separator

level.

Make

to

both

the

time

items:

to

maintain the

the

bowl

Inspect

certain

the

starter

to

the

plastic

or

after a

fuel

supply

wire

solenoid'

engine

recovery

level

and

for

connections

the

positive

and

ground

tank

NOTE:

refer

o

Visually

parts,
the

threaded

o

Make
engine.
perfonuance.

o

Make

o

Ensure

transmission.'

o

Open
to

the

If

the engine

to

the

COOUNG

exaruiue the

disconnected

connections

certain

there

Ao

ample

sure

the

mounting installation

the

propeller

the thru-hull

raw

water

strainer.

COOLANT
RECOVERYTANK

has

not yet been filled with coolant,·.

SYSTEM section

engine.

wires,

and

and

is

proper

supply

is

necessary

shaft

is

and

make

.

Look for loose or missing

unattached hoses. Check

engine attachments.

ventilation around the

securely attached

certain

of

this manual.

for

proper engine

is

secure.

raw

water

to

is

the

primed

.....

WESTERBEKE

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

CHECKLIST

Follow

D

D Check
D

D

D Check

D Look

D
D

D

this

check list

Visually

Check
Periodically

Check

transparent
Check

mounting
Check
Check

D

Visually

STARTING

1. Put the

NOTE:

neutral safety switch

energizing
transmission

energize.

inspect
the
the

the

your

for

clean

for

is

the starting

drive

inspect

THE

transmission

Hydraulically operated transmissions have a

oil
coolant

transmission

fuel

bowl.

loose

circuit

each

the

engine

level

(dipstick).

level

check

the

supply.

fuel

in

wires

secure.

batteries

belts

for

the

raw

ENGINE

in

passes.

is

in,

gear

day

before

for

in

the

manifold

fluid

the

fuel

at

the

(weeldy).

wear

and

water

neutral,

through

This

so

the

starting

fuel,

oil,

or

coolant

recovery

coolant

level.

level.

filter/water

alternator

which

starter solenoid

proper

pump

throttle

switch

and

tension

for

leakage.

advanced.

the

starter solenoid

is

open

your

engine.

water

leaks.

tank.

separator

make

sure

(weeldy).

when

will

the

not

its

NOTE:

Some

unstable running

the

Depressing

will help stabilize
temperature reaches

the

engine. "

fAILURE

If

the

engine

seconds,

5
procedure.

neutral

position

to

prevent

Never

run

fails

to

start, refer

this

manual.

PREHEATswitchfor 10-15 second intervals

TO

START

falls

wait

for

Make

certain

as

starting

the

starter

NOTE:

When

starting:

A voltage drop

when

the

is

depressed.

may

occur

the

engine

rpm

until

the

140 - 150' F and a load is applied

to

start

when

the

start button is

at

least

30

seconds

the

transmission

some

engines

in

gear.

for

more

than

to

the

TROUBLESHOOTING CHART

and

have

a neutral safety switch

30

seconds. If

will occur

preheat switch

in

a cold engine.

operating

repeat

control

pressed

the

starting

is

in

the

the

engine

to

for

in

2.

Tum

the

KEY

SWITCH

[Th~

panel

is

energized,

3. Depress

seconds

[The

is activated}.

4. Continue

the

engine}.

5. Release

6.

With
proper oil
check for

water

opens.

is

NOTE:

engine

It
Become

immediate

If

allow about 50 seconds for the

the

PREHEAT

depending

fuel lift pump

pressing

START

the

the

engine

pressure

overboard

temperature

Do

not

close

to

normal.

Never attempt

is

running.

is

important

aware

a "smart" regulator

how
is

the

BUTTON.

START.BUTTON

running,

and

will

engage

to

closely monitor

of

the

action

if

to

the

ON

position

gauges

are

lit}.

BUTTON,

cold

priming

PREHEAT

[The

check

battery

discharge

rise

the

gear

to

engage

normal engine readings and take

these

readings

is

part

hold

it

is.

the

engine and

BUIJ'ON

start motor

as

the

the

instrnments for

charging

of exhaust

slowly

until

shift

until

the

starter while the

the

start

of

the

RPM gauge

(2

o'clock).

for 5

to

15

the

preheat

and

press

is

cranking the

engine

starts.

voltage.

the thermostat

panel

to

charging system,

water.

the

temperature

gauges.

'vary.

to

activate.

Also

The

A

CAUTION:

engine
filling

with

pump

;s
cooling
enter

the
manifold
from

happening
through-hull
co"ecting

Engine
wa"antable

in

mind.

Stopping

To

stop

the

place

the

few

moments

a
engine

down

NOTE:

Make certain this key switch is in

position(I2o'clotk).lfthe key switch is left

energized instrument panel will put a

Prolonged

starting

can

raw

water.
pumping
system

raw

during

engine's

once

the

by

shut-off,

the

cause

damage

resulting

issue;

Procedure

engine,

bring

transmission

to

stabilize

by

turning

cranking

result

in

the

This

may

water

through

cranking.
cylinders
exhaust

closing

the

by

way

system

the

raw

draining

of

the

the

excessive

from

raw

owner/operator

the

throttle

in

neutral\

off

Allow

temperatures.

the

key

intervals

engine

happen

the

This

raw

of

the

fills.

walBr

exhaust

engine

water

should

to

an

the

switch

the

drain

without

exhaust

because

raw

water

the

system

the

water

can

exhaust

Prevent

thIs

supply

muffler,

and

cranking_

entry

is

not

a

keep

this

idle position and

engine

to

idle for

Then

shut

the

OFF

ON,

the

on

the

battery.

NOTE:

The

START

switch

will

no! energize unless

HEATswitch

activates

HEAT

is

depressed Depressing the PREHEATswitch

the

glow plugs

inter1l/.ittently

in

the cylinder head so use the

to

avoid overheating

the

glow plugs.

~

the

PRE-

PRE~

WESTERBEKE

Engines & 4,enerators

9

WARNING

L1GIITS,

ALARMS

&

CIRCUIT

BREAKER

ALTERNATOR

The

Captain

with a red warning light.
The

Admiral

performance

WARNINGS

Control

Control

of

the

alternator.

OIL

GALLERY

Panel

Panel

indicates

uses a voltmeter

alternator

low

to

monitor

discharge

the

COOLANT

A coolant
housing.

coolant's
(99'C).

temperature

This

operatiog

---

TEMPERATURE

switch

will

temperature

THERMOSTAT
ASSEIVIBLY,

switch

activate

SWITCH

is located

a continnous alarm

reaches

on

the

thermostat

approxiroately

if

the

21O'F

LOW

OIL

PRESSURE

A low

oil

pressure

block.

This

switch's sensor

sure.

Should

the

engine's oil pressure
(0.4-0.7
alarm.

ENGINE

The

mounted

Excessive

the instrument panel
breaker
because
this
After
engine.

kglcm'), this switch will activate a pulsating

CIRCUIT

DC

harness

to

the

should

repairing

on

manual reset circuit breaker

current draw

trip.

In

this event most engines' will shnt down

opeued

occur,

cbeck

the

alarm

ALARM

switch

SWITCH

is

located

monitors

the

fall

BREAKER

the

engine

is protected

(20

or

electrical overload

wiring

or engine wiring

breaker disconnects the

and

repair the source

fault,

reset the breaker

on

the engine

engine's oil pres-

to

5 -

10

psi

by

an

engine-

amps

DC).

anywhere

will

cause the

fuel

supply.

of

the

problern.

and

restart the

in

If

Engll1~s

& Generators

10' -

MAINTENANCE

SCHEDULE

In order

to
your

NOTE:

others

a! a service

to

use

log

your

engine

engine

hours

Many

of

are

more

mechanic.

SCHEDULED
MAINTENANCE

Fuel

Supply

Fuel/Water

Engine

Coolant

Transmission

Drive

Visual

Fuel
Starting

(and

Engine

Heat

Fuel/Water

Exhaust

Engine

Throttle

Conlrol

Adjusl

Raw

Inlel

Separator

Oil

Level

Level

Belts

Inspection

Filter

Batteries

House

Batteries)

Oil

(and

EXChanger

Separator

System

Hoses

and

Cable

Engine

Water

Pump

Fuel

Filler

this

Maintenance

hours.

by

running

the following maintenance jobs

difficUlt

and may

Use

CHECK

Schedule,

yor

engine

time.

require

EACH

DAY

hounneter

the expert knowledge

50

0
0

0

0

Fluid

Level

0

0

weekly

of

Engine

0

NOTE:

and

remain

0 0

0

weekly

filter)

Zinc

Anode

0

0

0 0 0 0

Transmission

Idle

Speed

0 0

0

it

will

be

necessary

or

record

A

while

are

simple but

equipment
cofrect

terminals
electrical

HOURS

OF

OPERATION

100

Please

oil

will

cool.

250

keep

inhibit

the

0

0

0

0 0 0 0 0

500

engine

engine's

0

0 0

750

1000 1250

surface

ability

0

clean.

0 0 0 0 0 0

0

0 0

0

0

0

0 0

0 0

0

WARNING:

the

engine

such

tools

when

equipment.

Dirt

to

0

0

0

0

0 0

0

0 0

Never
is

running.

as

goggles

for

each

servicing

EXPLANATION

Diesel

No.2

Check

for

water

if

necessary).

Oil

level

should

dipstick.
Check

at

recovery

Add

coolant

Fluid

level

on

the

dipstick

Inspect

for

and

adjust

Check

for

fuel,

and

electrical

Check

for

Initial

change

Check

electrolyte

and

make

excessive

Initial

engine

change

both

Inspect

zinc

exchanger
Change

every

Initial

check

for

leaks.

the

exhaust

buildup

on

necessary.
Hose

should

spongy.

Check

Check

for

Lubricate

"800-1000

Remove

Ihe

gasket,

cam

and

seals

Lubricate
Replace.

attempt

job.

rating

to

perform

Wear

the

proper

and

gloves,

Disconnect

any

Df

MAINTENANCE

of

and

dirt

indicate

the

engine's

OF

SCHEDULED

45

cetane

in

fuel

between

the

any

safety

and

use

battery

or

higher.

(drain/replace

MAX.

-

tank;

if

empty,

check

if

needed.

should

indicate

between

proper

tension

if

needed.

Check

oil

and

water

connections.

loose

belt

tension.

at

50

hrs,

then

levels

every

sure

connections

corrosion.

oil & filter

every

anode,

end

200

at

Check

elbow

inside

Check

be

loose

wilh

rpm (adjust for transmission

pump
and

(the

when

change

250

hours.

replace

of

zinc

anode

hours.

50

hrs.,

then

anti·siphon

for

carbon
passages;
that

all

connections

hard & tight.

and

tighten

fittings,

cotter

WD-40

or

equivalent.

cover

and

cover

for

shaft

can

turn,

reassembling.

(3/8"

belt

leaks.

Keep

change

50

are

if

needed,

debris.

every
valve

and/or

clean

Replace

all

hose

inspect

wear.

but

to

very

at

pins,

MAX

1/2"

edges

Inspect

bolts & nuts

every

operating

tight.

50

250

operation.

corrosion

and

clamps.

etc

Check

not

service

the

DC

filter

and

LOW

at

manifold.

and

LOW

deflection)

for

wear.

wiring

tight.

250

hours

Clean

hrs.,

then

clear

the

hrs.

Inspect

Check

replace

are

tight.

if

soft

or

used)

Ihe

impeller,

the

bearings

wobble).

on

hrs.

off

heat

as

""'"

WESTERBEKE

Engines & Generators

11

NOTE:

Use

engine

the

hours

MAINTENANCE

engine

hour

meter

gauge

by

running

time.

SCHEDULE

to

log

your

engine

hours

or

record

your

SCHEDULED

MAINTENANCE

Coolanl

Syslem

DC

Alternalor

Transmission

Engine

Transmission

Damper

Plate

*Fuelln/eclors

*Slarter

*Preheat

with

Molor

Circuli

*Engine

Cylinder

ComRression

*Adjusl1he

*Heal

Lubricale

Transmission

Valve

Exchanger

Panel

"Lockeze"

Oil

Cooler

Clearances

Key

Swilch

Fluid

CHECK

EACH

OAY

HOURS

OF

OPERATION

50

100

250

500

750

1000

D D

D D D

D
D

D

D D

D

D D

D D D

D

D D D D D D

D D D D D

1250

D

D

MAINTENANCE

Drain,

flush,

and

refill

appropriate

Check
bracket;

Remove;

tested.

Chattering
of

damper

Check
spray

Check
and

pinion
Check

clean
element

compound

Check

Adjustments).

Adjust

ADJUSTMENTS).

Remove,
tested.

At

Initial
300

antifreeze

DC

charge

tighten

have

professionally

at

idle

plate

and

adjust

condition.(see

solenoid

lubricate.

first

hours

Clean

drive.
operation

glow

plugs,

(0.9

Ohm).

.on

compression

Valve

Clearances

have

100

hours,

fluid

change

or

at

from

electrical

and

wear.

injection

and

of

check

the

professionally

winterizing.

DESCRIPTION

cooling

mix.

alternator.

connections.

low

rpms

Remove

opening

ENGINE

motor

for

and

lubricate

preheat

solenoid.

resistance

Reinstall

threads.

pressure

and

(see

ENGINE

Ihen

each

at

25

hours,

system

with

Check

mounting

cleaned

and

pressure

is

an

indication

and

replace.
pressure

ADJUSTMENTS)

corrosion.

the

value

with

timing

cleaned

year

at

then

'and

RemoVe

starter

motor

Remove
anti-seize

winterizing.

every

of

(see

and

and

heater

Engine

pressure

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

"'SoY"

WESTERBEKE

Engines'& (ilenerators

12

mechanic.

/

DESCRIPTION

Westerbeke
for

fresh

bustion

which
water
parts,
from

exchanger.

water
fresh
ferred
tube
exhaust
other

coolant

transferred

fresh

each
allows

harmful

RAW

A

major

boatyardlbuilder

marine

water

and

friction

circulates

coolant

cools

and

the

the

fresh

similar

flows

through

water

coolant

to

the

fresh

walls

to

the

system

words,

the

is

cooled

heat

water

coolant

other.

Using

the

cooling

deposits.

WATER

part

of

diesel

cooling.

is

throughout

the

engine

water

in

flows

water

raw

where

engine

by

overboard

and

only

water

INTAKE

the

raw

installed

engines

Heat

produced

transferred

the

engine

block;

oil.

The

heat

coolant

the

raw

function

tubes

around

coolant

water

which

finally

is

cooled

water,

through

raw

fresh

passages

to

to

of

it

water

water

STRAINER

water

cooling

intake

are

designed

in

the

engine

to

fresh

water

engine.

This circulating

its

internal

is

transferred

raw

water

by

means

an

automotive

the

heat

exchanger

the

tubes;

engine

is

conducted through

is

then

pumped

is

discharged

by

fresh

and

the

the

circuits

coolant within

to

stay

strainer.

overboard.

water

raw

water

exhaust

are

clean

system is a

COOLING

and

equipped

by

com-

coolant

fresh

moving

externally

of a heat

radiator.

coolant,

system.

independent

and

while

heat

the

into

the

carries

The

the

engine

free

proper

Raw

trans-

In

this

the

of

from

SYSTEM

FI~TER

TYPICAL

INCOMING
RAW

WATER

SEACOCK-~""

RAW

WATER

(Owner

Installed)

-....;::-,::.==-;;;><

.

INTAKE

STRAINER

/

INSPECTANO

.

CLEAN

EVERY

laa

HOURS

NOTE:

Always

the

strainer

A

clean

engine's

strainer
in

the

glass

Perform
operation:

1. Close the raw water seacock.

2.

Remove

3.

Clean

4.

Replace

5.

Reassemble

6.

Open the seacock.

7.

Run

NOTE:

raw

cooling

when

the

the

the

Also

install

will

always

water

intake strainer

system.

making

should

following

and

clean

glass.

the

washer

and

engine

follow

the

the

strainer

be

self-priming.

Include a visual

your

be

clear.

maintenance

the strainer

if

necessary.

install

and

check

above

periodic

the

strainer.

for

procedure

aground.

If

the

engine
normal
may

have

raw

water

temperature

reading,

been

through

the

caught

cause

the

gauge

may

up

in

cooling

be

the

system.

at

or

below

the

waterline

is

a vital component of

inspection

engine

check.

after

every

100

filter.

leaks.

after

having

ever

shows a higher

that silt, leaves

strainer,

slowing

of

The

hours

run

or
the

this
water

than

grass

flow

so

the

of

hard

of

DRAINING

When
protect the
from

This

water
intake valve before disconnecting the hose. Insert
end

into a

Before starting

(replace the
of water
Hnshing is complete.

Run
cooling

~

Provide
maintain the
operated

The

fresh water

. exhaust

probability of
then
supply

through the
for both

When
seacocks
water.

water

THE

RAW

freezing

damage.

procedure

intake

the unit for \0

..

prior

recommissioning,
if

can

raw

hose

large

gasket

Ibm

the

system.

---.

-.

an

external

water

during

lines.

If

freezing,

to

shutting

with

a concentrated

engine

the

engine

are

open

the

engine

stay

temperatures

water

is

best accomplished

from

container of

the

engine.

-

the

will

the

in

WATER

cooling

the

engine,

and

cover).

Re-install the thermostat once

minutes

fresh

level in the bucket while

fiushing

- .

fiush

engine

flush

the unit

to

provide

and

exhaust

so

the engine

is

stowed

the

engine.

are

circuit

vessels

fresh

remove

This

or

longer

water

process.

out the

is

being

the

down

antifreeze

freeze

make

where

SYSTEM

expected,

and

engine

by

disconnecting

Ibm-hull

water.

the

engine thermostat

will

ensure a

to adequately

supply

for the bucket

engines
engine

system.

certain

will

water

stored

with

substitute the

mixture

and

corrosion

the

quickly receive

it

is

warm,

it

is

fitting.

the

and

fresh

valves

best

passages

there

and

to

e)(haust

the

Close the

the

full

flow

flush

to

unit

is

is

water

fresh

run

protection

and

fresh.

the

fresh

hose

the

being

and

a

and

water

this

Engines & Generators

13

COOLING

SYSTEM

THERMOSTAT

A thermostat, located near the manifold
engine, controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit.

When the engine is first started, the closed thennostatpre-

vents coolant from flowing (some coolant
through a hole

manifold from overheating). As the engine warms up, the

thermostat gradually opens. The thermostat
and

can be checked, cleaned, or replaced easily. Carry a

spare theimostat and gasket.

COOLANT

PRESSUIRE

in

the thermostat to prevent the exhaust

CAP--\\

(KEEP

CLEAN)

at

~7''''

PASSAGE

the front

is

by-passed

is

accessible

,

___

~

of

THIS

HOSE

~-assemble

( tighten the three screws.

l~

the

CLAMP

REPLACING

1.

Drain

and drain
thermostat housing. This can be done using
exchanger drain plug.

2. Rotate the
as shown and remove the three allen screws that hold

down the thermostat housing cover, the assembly

be

twisted enough

3. Remove/replace the gasket

installing the new parts, apply a thin coat
both side

hose clamp and tighten the dntins.

mn
leaks around the thermostat assembly.

THE

THERMOSTAT

off

some coolant: Release the coolant pressure cap

the

coolant to the approximate

thermostat

of

the gasket before pressing it into place.

:n;:t:

the engine. Check for normal temperature and for any

assembly: Loosen

to

access the gasket and thermostat.

and

HEAT
EXCHANGER

Thm

the cover

Do

not over-tighten! Tighten the

level

the

the

thermostat:

of

sealant

back

Top

off

the coolant and

into place and

off the

heat

hose clamp

can

now

When

on

THERMOSTAT
ASSEMBLY

GASKET

SEAL

WITH

Hh'A"'i

COOLANT

A

down
is

the

temperatures

1I'1r)+---JIIR

CAUTION:

before

attempting

surface

.

PETCOCK

THERMOSTAT

HOUSING

of

can

BLEED

COVER

The

the

be

engine

these

engine

at

190·

lIJust

be

allowed

procedures_

hot

but

coolant

F.

to

Not

cool

only

SWITCH

I;ng/nes.& GllheratQrs

. 14 . .

COOLING

SYSTEM

FRESH

NOTE:

ommended
fresh

Fresh

'Iating

then
heat
block

When
vented
is
manifold
thermostat

coolant

coolinll

WATER

Refer

water

water coolant

pump,
passes thrqugh
exchanger

via

the

by

bypassed

to

s¥stem.

TO

COOLANT

RECOVERY

FROM

COOLANT

RECOVERY

to

the

antifreeze

coolant.

absorbing

the

suction

engine

the

closed

around

from

overheating).

gradually

flow

TANK

TANK

COOLING

ENGINE

and

water

is

pumped

heat

the

thermostat

where

it

is

cooled,

side

of

is

started

cold,

thermostat

the

thermostat

opens,

unrestricted

CIRCUIT

COOLANT

mixture

through

from

the

engine.

into

and

the

circulating

external

(although

to

prevent

As

the

engine

allowing

to

KEEP

COOLANT

the

external

THE

CLEAR

full

section for

to

be

used

the

engine

The

the

manifold,

returned

to

pump.

coolant

some

coolant

the

exhaust

warms

flow

of

portion of

PASSAGE

the

rec-

as

the

by a circu-

coolant

to

the

the

engine

flow

is

flow

up,

the

the

engine's

the

CHANGING

The

erigine's

MAINTENANCE

become

A

CAUTION:

critlcalj a substantial

traced

Drain

pre-

engine
the

system

NOTE:

to

help

~

the

block

The

drain

ENGINE
fl00LANT

~"~

COOlANT

coolant

SCHEDULE.

contaminated,

Proper

back

to

cooling

engine

coolant

and

opening

with

fresh

drain

on

the

engine

BLOCK

DRAIN

must

be

changed according

If

the

it

can

lead

to

overheating problems.

cooling

number

system

by

the manifold pressure

water,

heat

coolant.

system

of

engine

corrosion.

loosening

then

start

exchanger should also

coolant

is

allowed to

maintenance

failures

the

drain

the

refill process.

OIL

to

the

is

can

be

plug

on

the

cap.

Flush

be

used

GALLERY

COOLANT

NOTE:

Periodically check

pressure

good
the
closes tightly. Cany a spare

cap.

cooLant
coola:nt

able to expand

to

Coolant

A coolant

and

cant

ing
engine

NOTE:

located at or above

cap.

Ensure

conditiOl~

vacuum.

Check also

passa.ge

within

andfrom the coolant recovel)'tank

Check

valve opens

to

is

the

and

Recovery

recovery

contraction

loss

system.

manifold

TI.;s

during

of coolant

This

tank

level

tank,

with

the

condition

the

upper

to

ensure

and

ensure

the

clear so

system is

contract

Tank

tank

allows

for engine coolant

engine

operation,

and

without introducing air into

should

be

and

should

its shOlt run

the

level

of

RETRACTION

of

the

and

lower

rubber

without

located at

be

the

or

easily accessible.

of

plastic

engine ~ manifold.

manifold

seals

expansion

any

above

the

hose,

is best

are

signifi-

the

cool-

ill

.

SEAL

Refilling

After
coolant
the
the

housing.
Monitor

the
from
install

Remove
coolant
the
flow

stat
J\fter checking

Coolant
engine

needed.

A

Wear

the

closing

into

the
manifold,
air

bleed

the

manifold

the

petcock

the

pressure

the

mix

cap.

Run

into

the

housing

should

cools

Clean

WARNING:

protective

Coolant

the

engine

manifold

start

the

petcocks

coolant

to

the

is

cap

on

to

halfway

the

engine

recovery

is

free

for

draw

down.

up

any

block

and

engine

and

on

the manifold

in

the

manifold

filler

neck

free

of

air

cap.

the

coolant

between

and

observe

tank.

When

of

air

bubbles, close

leaks,

stop

back

into

Add

coolant

spilled coolant.

Beware

of

gloves.

drain,

when

run

and

when

bubbles,

recovery

LOW

the petcock

the

engine

the

cooling

to

the

hot

pour

clean, premixed

the

coolant

it

and

and add

close the petcock

and

the

the

recovery

engine

is

at

slow

idle.

the

thermostat

as

needed. Fill

the coolant

tank and

MAX

coolant expansion

on

that

petcock.

and

allow

system

coolant.

visible

Open

flowing

fill
and

the

it to

as

tank if

in

and

with

replace

thermo-

cool.

the

'~/WESTERBEKE

""

_ ,

__

::1

..Enaines & Generators

15

RAW

WATER

The

raw

impeller

ocean,

lake,

raw

water
exchanger
the engine'circulating
then

discharged

ing

with

exhaust

Raw

Water

The

raw
non-ferrous housing

flexible

has

within

the

On

no

account
lubricant
impeller

Raw

water

water)

is

are

not

warrantable,

raw

water

NOTE:

Should
(seals and bearings),
purchase a new pump and
a

spare.

Inspecting/Changing

Close

the

and,

with

impeller out of the

a pair

of

care

not
gasket.
and

push

assembling,

gasket.

and

the

Run
check

for

flow

indicates

NOTE:

Never allow

of

dry

running

water
pump.

or

passes

(through

and

gas

and

cooling

COOLING

flow

This

river

from

into

raw

CIRCUIT

is

created

pump

draws

through a hose

the

strainer

the

heat

exchanger

fresh

water

the

water

the

exhaust

water

is

Pump

water

pump

is

a self-priming,

and

a neoprene

vanes

which

wipe

impeller

for

and

pump

not

flo~

housing,

should

this

the

impeller.

impeller
present

afailure occur

impeller

is

present

cover

during

and

operators

it

may

pump

There should

gasket

failures

engine

at

st~-up.

be

rebuild

the

raw

water

intake

valve.

the

proper

size

impeller

pump

(the

screwdrivers if

to

tear

the

Move

the

the

impeller

apply a

Open the raw water intake

~ngine

and

water

discharge

the

may

RAW

impeller).

blades

into

thin

check

pump

the

pump

destroy

WATER

PN52650

an

impeller puller

to

conform

the

coating

for

at

has

the

PUMP

by a positive

water

directly

to

the

through

tubes)

coolant.

injected

pushed

against a

producing the

with

Raw

impeller

Install the

pumps

leaks

the

not

to

exhaust

gasses.

This

overboard.

rotary

impeller.

curved

be

run

dryas water acts

always

aboard

occur

operation.

are

cautioned

the

pumps

more

cost

the

original

Water

Remove

tool,

carefully

can

new

to

the

housing.

of

lubricant

around

stem

tube.

primed itself

run

dry.

impeller.

when

COOLING

displacement

from

the

water

strainer.

the

heat

where

it

cools

The

raw

water

elbow,

mix-

mixture of

pump

with

The

impeller

cam

plate

pumping

(an

efficient

Pump

the
be

is

curved

valve.,

the

Absence

Even

action.

be

a spare

impeller

lubricani

Such

failures

to

make

internal parts

to

pump

as

Impeller

pump

cover

pry

the

pried

out

unavailable.

impeller

to

and

cam

When

the

impeller

' .

pump.

Also

of

properly.

a short period

The

is

a

as

kit).

(raw

sure

using

Take

plate

w.(lter

SYSTEM

a

Heat

The
ber of
small
engine
removes

Zinc

A zinc

circuit
anode

in

of
dition of

anode

be

NOTE:

install~tion

If the
which
ening
boss
removing
poor
the

clean
exchanger
aged
to your engine model's

ber),

Exchanger

heat

exchanger

small

copper

copper

tubes

is

circulated

heat

from

Anode

anode,

or

pencil,

within

the

heat

is

to

sacrifice

the

raw

water

cooling

electrolysis

cleaned

carried

Electrolysis action is

zinc

the

from

condition,

exchanger.

the

when

a-ring,

the

the

anode

inside

on

pencil

zinc

possibly

the

end

on

other

zinc

anode

or

replaced

board.

and vessel

needs

pencil

with

zinc,

there

Remove

of

gasket

removing

cover,

NEW:'

is a copper
tubes.

Raw

and

the

freshwater

around

the

the

freshwater

is

located

exchanger.

itself

to

circuit,

components

should

as

location;

replacement,

is

threaded

another

tearing

off

note

the

are

probably

the

all

zinc

debris.

in

case

the

end

heat

and

install a new

BAD

BA~

ZINC

ANODES

tube

which

encloses a num-

water

is

pumped

coolant

copper tubes. The

coolant.

in

the

raw

The purpose of

electrolysis action taking place

thereby

be

required.

the

result

not that

wrench.

the

condition

end

of

the
cover.

exchanger

reducing

of

ttie

checked

Spare

of

each particular

hold

with

a wrench while loos-

This prevents the hex

exchanger shell. After

of

a lot of

the

heat

Always

present

Replace

end

zinc

through the

from

the

raw

water

water

cooling

the

zinc

the

effects

system. The con-

monthly

of

the

the

it.

If

zinc

exchanger and

have

one

gasket

pencil.

and

anodes

should

generator. '

hex

boss into

the

zinc is

flakes within

a spare heat

becomes dam-

the

gasket (refer

part num-

the

in

INSPECTION:

EACH

REPLACE

ANY

CHECK

BLADE

BY

THE

CRACKS,

THE

BENDING

IMPELLER

BASE

OF

VIGOROUSLY.

IF

THERE

ARE

~

Heat,

Exchanger

After

approximately

and

pressiIre

, motive radiator

, .

'::

exchanger.)

NOTE:

Operating
that a heat exchanger cleaning
every 1000

WESTERBEKE

Englnes'& Generators

16

test

shop

hours.

Service

1000

hours

the

engine's

should

in

silty and/or tropical

be

heat

able

be

of

operation,

exchanger.

to

performed more often

clean

waters

remove, clean

(A

local

and

test

may require

auto-

the

heat

than

WATER

HEATER

WATER

These engines are equipped with connections for the
of
The water heater should be mounted in a convenient location
either
that the connecting
run in a reasonably direct line without
trap

Hoses
heater io the engine
heater to the engine.
then
on

HEATER

engine coolant to transfer heat

in

a high

air.

SllOUld

an

air bleed petcock must lie installed at the higher

the

heater for bleeding air while

THERMOSTAT

INSTALLATIONS

to

an on-board water

or

low position in relation

hoses

from the heater

rise continuously from their low point

so

that air will rise naturally from

If

trapped air

HOUSING

is

able

filling

to

to

any

loops which might

to

the system.

the engine,

the engine can

rise to the

!

plnrnbing

heater.

so

at

the

the

heater,

fitting

NOTE:

If

any

portion
engine's
remote

circuit

tank
connections
single

engine ~ retz{m.

convenient
The
system
when
tank

recovery

The pressure cap
installed after
coolant. Finish filling the cooling system

tank after the system

good
the engine's coolant should be done at the remote
not
heater
supported so it rises continuously from the
enabling any

of

own

expansion

to

become

into

the

heater

for

line

up

location

remote

expansion

fill

point.

the

remote expansion tank kit

serves

the

tank if it

coolant circulation. During engine operation, checking

at

the engine manifold cap. The hose connection from the

to

the remote expansion tank should be routed and

the

system.

of

the

heating

pressure

to

the

.air

cap,

then

tank

(Kit

#024177)

the

highest

point.

circuit,

choosing

the

return.

Tee

at

the

tanks

location

Install

the

remote

so

the

coolant

tank

will

The

plastic

coownt recovery tank is not used

same

function.

has

been

on

the

engine's cooling system

is

filled

in the system

Remove

already

engine's manifold should be

and is free of air and exhibits

to

circuit

rises

abov~

a pressurized (aluminum)

must be installed

Tee

the

remote

the

higher

the

heater,

and plumb a

and

the

other back

expansion tank

level

can

easily be

now

serve

as

a check and

is

installed, since this

and

store

installed.

is

filled with

from

the

heai:er

rise up to the tank and out

the

expansion

of

the

two
to

in

a

checked.

the plastic

remote

tank

and

to the tank,

in

the

the

WATER

HEATER

---

~.-:--

~

.

OWNERS

:

FROM

HOT

CONNECTIONS

HOT

WATER

WATER

NOTE:

An air bleed

heat

exchanger.
coolant
Close

tightly after

HOSE

TANK

system

petc~ck

Open

to

allow

all

REMOVE
TANK

(024177)

is

this

petcock

air

in

the

air

is

EXPANSION·

located

when

the

exchanger

removed.

I

on

the

·engine

filling

the

to

escape.

's

engine's

I'W'IiTIWESTERBEKE

I

Enaines

...

""

-17--

&.

GtmeratorS:

FUEL

SYSTEM

DIESEL

Use
#45
In conjunction with Ultra Low Sulphur Diesel.
additive such as Diesel Kleen + Cetane Boost to help restore
lubricity back into the diesel.

fUEL

A

installed between the
water
be

A
diagram. This

that if a water separator type

~uel

l~

lIon equipment. The owner/operator
certain
free of impurities. This
and maintaining a proper filtration/separation

FUEL

The fuel injection pump is
the diesel engine, requiring the utmost caution in handling.
The fuel injection pump has been thoroughly bench-tested

and the owner-operator is cautioned not to attempt

it.

authorized fuel injection
attempt
shims with the injection pump, leave on engine.

FUEL

No.2-D
or

primary

carried

typical

supply

the

If

it requires servicing, remove it and take it to

(SAE

J3l3)

diesel fuel with a Cetane rating

higher. Grade

WATER

fuel

and

other contaminants

to

the fuel system

fuel

filter/water separator

tank and engine-mounted fuel system,

fuel

will

the

fuel

INJECTION

to

disassemble and repair it. Do not send the timing

of

diesel

fuel

SEPARATOR

filter

of

the water separating type must be

fuel

tank

and

from

on

the

is

the Raycor

affect the
reaching

TYPICAL

FILTER/WATER
SEPARATOR

Model

filter

fuel

pump,

the

enSine's injection equipment is

process

FUEL

is

PUMP

the

most important component

pump

service

according to ASTM D975.

the engine

the fuel before they can

engine.

is

illustrated

500

MA.

is

not

installed between the

engine

is

responsible

accomplished

facility.

to

Keep

filter,

by

system.

10

micron

element

Do

Use

an

remove

in

this

in

mind

any

water

and

injec-

for

making

installing

filter

recommended.

of

to

service

an

not

of

ENGINE

Periodically
leakage.

the

Changing

1. Shut

2. Unscrew

3. Wipe

4.

5. Install the

6.

FUEL

check

Change

MAINTENANCE

the

off

the fuel

NOTE:

Slide

as it

will

cartridge

both

with

clean

To

help

reduce fuel system priming, fill the fuel filter

with

diesel
reduce the pliming
engines

Open

fuel system before starting.

the

filTER

the

fuel

connections and the

the

filter

element

after

the first

SCHEDULE.

Filter

Cartridge

supply.

a plastic

be

full

the

cartridge from its housing and remove the

and

its gasket. .

the housing
fuel.

before installing. This will dramatically

new

fuel

bag

of

fuel.

and

time

needed to purge air from the

cartridge and

supply.

Run

up

over

the

the

top

of the

spin

on

the engine to inspect for leaks.

LIGHTLY
WITH

CLEAN
WHEN
THE

NEW

FILTER

filter

50

hours. See

fuel

filter

new

cartridge

real

tight

WIPE

FUEL

INSTALlING

FUEl

CARTRIDGE

by hand.

bowl for

cartridge

LIFT

PUMP

BlEEOSCREW

The bleed screw on the injection
open position. This wili then

engine's

air in the system

fuel return system.

fuel

system and during engine operation allow for

to

be delivered

pump

should be left

allow

for ease

to

the fuel tank through the

in

priming the

in

the

Engines & Generators

...

··1-8---

FUEL

FILTER

CARTRIDGE

JtJOOCl

FUEL

LIFT

PUMP

Periodically check the
pump

and

make

sure that

fittings

are

tight

and secure. The

one

of

the

pumps

mounting bolts should be
secured
operations.

INLET

To
in-line
filter

by

FUEL

ensure

fuel

should

the

mounting bolts

FilTER

clean

fuel into the fuel lift pump,

filter

connected

be replaced every

fuel

connections

no

to

leakage

DC

to

ensure proper

the fuel lift

250

hours of

to

and

out

of

the

is

present and tllat the

ground connection at

clean

and well

pump

there

is

a small

pump

elbow.

This

operation.

ENGINE

1.

OIL

Draining

the

sump

while

the
replace
securely.

NOTE:

Thread

is

JI4NFT.

CHANGE

the oil

drain hose

engine

the

hose in

size

sump.

(attached

is

warm.

its

for

the

Discharge

Drain

bracket

lube

oil

the

to

the front of

the used

and

replace

drain

hose

ENGINE

used

oil

the

oil

completely,

the

capped

LUBRICATING

through

engine)

end

cap

elld

OIL

I •

••

APPLY

CLEAN

ENGINE

OIL

INSTALLING

Always
yellow/gray
the
prompt
qualified
Raw
the
siphoning
circuit
often
poor

2.

NOTE:

ooserve

oil.

Although

attention

water

exhaust

into

caused

location

Replacing

filter,

you

in

the

oil

from

to

lessen

should

Do

make

certain

Place
filter

when

(Oil

or
cooling
oil

filter

sealing

sealing
gently

When
gasket's sealing surface
apply
on

the

filter

firmly

NOTE:

through

the

emulsion

this

to

mechanic should

present in

system attached

of

raw

water

the

exhaus~

by

the

or lack of

the ailfilter.

may·

find

upper and lower

it

into a container before

spillage. A

be

helpful

not

punch

it

can

some

paper towels

unscrewing

any

other

ability.

as

it

is
gasket comes off
gasket remains

remove

installing the

a thin coat of

new

oil

nipple

on

by

hand.

The

engine

passages

used

oil

as

it

is

removed.

indicates

condition

prevent seriousdarnage.

the

absence

it

in

this

be

fluid

Keep

removed

it.

filter.

the

oil

oil

in

the

the

presence of

is

rare,

water

be

present

oil

can

be

the result of a

to

the

engine
through
filling

small

removing

hole

the

raw

the

engine.

of

an

anti-siphon

maintenance.

When

removing

helpful

and

portion

of

automotive

the

without

first

cleaner

the

removing

old

removed.

and

a plastic

it

to

catch

any

on

the

engine

your

engine clean.) Inspect

to

make

sure

with

the

old

sealed

against

new

oil

filter

elemen~

on

the bracket

clean

engine

oil

Screw

the

filter

filter

bracket,

is

cooled

by

enginecoolantfiowing

oil

filter

brack.et

it

and

A

water

does

require

Call

in

the

and/or

water

cooling

This

problem

valve,

the

used

to

punch a hole

old

filter

it.

filter

wrench

oil

filter.

loosening

bag

around

oil

left

reduces

that

the

filter.

If

the

filter

wipe

free

of

to

the

rubber gasket

onto

the

tighten

housing

'+-Smm

FOR

114"

REMOVE

.

TO

OIL

in

a

oil.
fault

in

a

its

oil

to

drain

This

helps

the

filter

the

in

the

filter.

the

engine's

the

rubber

this

rubber

bracket,

the

oil

and

threaded

the

assembly

[11/161

EXTENSION

NPT

USING

DRAIN

THE

THRU

the

OIL

THE

UP

is

to

old

filter

oil

filter

SOCKET

AN

8MM

(17176'/

OR

PUMP

HOSE.

NOTE:

SOCKET

THE

WARMED

Generic
material standords or
generic
parts.

3.

A

parts might

Immediately

run

the

engine

and

that

there

Filling the

cap
engine

pressure.
oil

filter
Then check
Fill
the engine

on

the
for a few

to,

but

Oil

top

Make

or

from
not

require

WARNING:

contaminants.
and

nails

thoroughly
discard
used

clothing

oil

properly.

OIL

FILL

r

___

/

filters

are

not

recommended,

diameters

be

entirely

after

an

to

make

sure

are

no

oil

Sump.

Add

of the

engine.

moments while checking the

sure there is

the oil drain

the

quantity of oil

over the high

additional

USed

engine

Avoid

prolonged

using

or

rags

containing

oil filter

the

leaks

new

soap

of

different

oil

around

oil

After

no

leakage

system,

with

mark

oil.

oil

contains

skin

and

refilling, run

on

l!3

as

the

important items

from

genuine

change

and

oil

pressure

through the

the

is

normal

the

new

oil

oil

the

oil

around

the

and

stop

the

lube

oil

dipstick.

the

dipstick, should

harmful

contact.

water.

used

Clean

Launder

oil.

Discard

on

fill,

filter.

filler

new

engine.

skin

or

Engines.

19

&.

Generators

INSTALLATION

This

popular

filter

an

engine

NOTE:

instnlctions

APPLY A THIN
INSTALLING
TIGHTEN
CONTACTS

from

Refer

AN

accessory

the

engine

room

bulkhead.

to

ENGINE

on

removing

COAT

OF

THIS

KIT.

THREAD

ADDITIONAL

THE

BASE.

CLEAN

3/4

is

used

to a more

OIL

CHANGE

the

oilfilter.

OIL

TO

THE

THE

KIT

ON,

TURN

AFTER

REMOTE

to

relocate

convenient

O·RING

THEN

THE

in

WHEN

HAND

O·RING

the

engine's

location

this

OIL

such

manual

FILTER

oil

as

for

(OPTIONAL)

To

install,

simply

remove
WESTERBEKE's
install

this

kit

Contact

NOTE:

your

Westerbeke

incorrect installation

A'

CAUTION:

rectly.

If

pass

valve

from

reaching

failure.

If

immediately

remote

with

the

oil

WESTERBEKE

is

not

of

It

is

the

oil

flows

in

the

filter

the

engine

there

is

no

and

check

.

the

engine

oil filter

filter facing

responsible for

the

vital

in

assembly

ai/

pressure

the

dealer for

Remote

to

install

the

reverse

causing

hose

kit

Oil

will

connections.

FASTEN

oil

filter

as

shown.

down

as

more

engine

Filter.

the

ai/lines

direction,

prevent

an

internal

reading,

SECURELY

(SCREWS

ARE

and

thread

Always

illustrated.

information

failure

due

cor-

the

by-

the

oil

engine

shutdown

TO A BULKHEAD

OWNER

SUPPLIED)

on

to

NOTE

THE

"IN"

ON

THE

ADAPTER
REMOVED
WILL

BE

RECONNECTED

"OUT"

WHEN

FOR

INSTALLATION

MARKINGS

THE

HOSES ARE

SO

THEY

CORRECTLY

i

THE

IN

CONNECTION

MUST

ATTACH

CONNECTION

/H'MU"OIL

THE
MUST

ATTACH
CONNECTION
REMOTE

OIL

TO

THE

ATTHE

FILTER.

TO

THE

ATTHE

FILTER.

HOSE

OUT

•

HOSE

IN

APPLY A THIN

GASKET

WHEN

CONTACTS

3/4

THE

TURN.

COAT

OF

INSTALLING.

BASE,

TIGHTEN

OIL

AFTER

IT

AN

TO

THE

FILTER

THE

FILTER

ADDITIONAL

Engines & Generiitors

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ADJUSTMENTS

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NOTE:

C

Disconnect
loosen
and
bending

2.

Using
its
lose
lbe

NOTE:

prior
any
hole.
by
side

it

and

3.

The
ing
injector
tor

INJECTION

1.

Using
tion

limit,

tester,

a.

,If

replace

b.

e.

d.

e.

THE

Injector

the

move

the

a

17mm

entirety

the

two

fuel

return

Clean

to

lifting

rust

or deb/is

If

the

carbon

with

then

injector

washer.

and

is

reinstalled.

must

the

lines

them

from

injecto.r

build

the

lift

This

TESTING

the

nozzle

~tarting

adjust

take.

tile

the

diesel

it.

Set

the

nozzle

dust

or

dirt.

Mount

the

tester.
Use·the

of 68' F (20· C)
Operate

bleed
lever

ing

at

the

fueIat

the

the air in.the

intervals

injection

INJECTORS

be

selViced

high

at their
out

lines.

long

the

sealing

line

the

area

it

out

from

up

aid of

it

out.

seats

washer

replaced

tester,

pre~sure

or

replace

following

fuel

At

the

tester

nozzle

the

Iland

in a "clean

pressure

attachment

of

the

way

socket,

top

of

the

washers

to

each

injector.

around

of

the

cylinder

falling

will

not

or

the

like,

the

17mm

in

the

cylinder

should

with a new

check

of

nozzle

the

nozzle.

precautions:

of

the

nozzle

same

fune,

in a clean

and

nozzle

approximate

lever

of

hOzzle

of

one

strokC

starting

pressure.

lines

remove

injectors.

and

the

lift

deep

the

clean

nozzle

lIne,

room"

from

to

the

of the

injectors.

the

banjo

base

head

down

into

out

easily

work

the

socket

head

be

removed

washer

spray

and,

if it

When

tester

or replace

place

holder

temperature

tester several

then

per

second

,

enviromnent

Ille

injectors

injection

Avoid

fuel

return

Thke

care

bolt that

of

attaches

the

injector

to

help

the

inj~ctor

and

is

held

injector

wrellch

on a copper

with

when

the

pattern

and

exceeds

usIng

nozzle

is

discolored,

the

where

there

on

the

nozzle

move

Ille

while

and

pump

line

not

to

prevent

in

side

to

to

free

seal-

the

injec-

injec-

the

filter.

is

no

funes

hand

read-

in

to

Inspecting

1.

Operate
on.e
rectly
injects
strips.
defect.
ging
cleaned
expose
and

2.

Apply
by
nozzle
on

replaced. A very

remaIn

indicate a defect.

The

injection

increasing

Pressure variation with

adjustIng

Spray,Pattern

the

hand

stroke

per

second

in

its

axial

fuel

in

an

Also, a spray

These

defects

with

dust

and,

before

reassembly.

ones

skin

cause

infection.)

the

pressure

operating
the

the'

tip.

If

it

drips

bottom,

it

on

the

tip

starting

or

decreasing

",asher thickness.

lever

directiori. A nozzle
oblique

to

hand

is

small

of

the

to

check

direction

in

tile

form

may

sometimes

therefore,

(Care

this

spray

..

~

1J

I~

p}

~!l'\'

""'.

1'1'1.

CHATTERING

of

1991

kg/em'

lever,

or

has a large

considered

amount

of

the

nozzle;

DRIP

pressure

for

the

thickness

O.01mm

235

nozzle

if

tlle

or

of

particles

all

parts

should·be

as

it

..

FAULTY

TEST

and

check

defective

of

fuel

however,

TEST

the

(O.004In)

kPa

may

tesler

at

intervals

fuel

is

injected

is

defective

in

several

be

should

penetrate

separate

indicates a

caused

be

taken

I@

.....

~

II,

-~I,

h

~I

'II

';0,

(140

Ib/in')

the

drips

accumulation

and should

may

sometimes

this

does

injectors

of

is

adjusted

the

adjusting

difference of

(2.4

kgflcm', 4 psi) .

of.

Cor-

ifit

by

clog-

carefully

not

to

tile

skin

;FAULTY

to

iJ(izzle

from

the

of

fuel

be

not

shim.

ADJUSTING

by

A

CAUTION:

sf

such

the

skin

it

enters

pOisoning.

FUE{

INJECTION

FACTORY

·13.73

-14.71MPA

,140 -150

1991 -2134

PRESSURE

SPECIFICATIONS

kgf/cm'

psi

The

velocity

of

fingers

the

bloodstream,

spray

that

and

injected

it

may

hands,

it

from

penetrate

destt-oying

may

cause

the

nozzle

is

deeply

into

tissue.

If

blood

/.INOZZLE

INJECTION.

'""'" WESTERBEKE

. _ .E'lglnes

Qt

__

QEmerator~

23

. i

TYPICAL

VALVE

TIGHTNESS

1.

Set

2.

Raise

(130kgf/cm',

3.

If

a

!

SHIM

THICKNESS

~

INJECTOR

the

injector

the

fuel

fuel

leak is

.

"·FACTORY

ND

nozzle'to a

pressure

1849

fuel

and

psi)

for

found,

replace

SPECIFICATIONS

leak

at:

nozzle

tester.

keep

it

at

10

seconds.

.the

nozzle

12:75MPA
130

kgf/cm"

.1849

psi

12.75

piece

.

MPa

.

GLOW

PLUGS

A

WARNING:

.

to

the

touch.

testing

plugs.

To

inspect

then

unscrew
Thoroughly
and

cleaning

While

cleaning,

has

eroded

An

accurate

Touch

one

other

to

the

will

have a 0.9

the

plug

in

test

the

power

Re-install

plugs

should
seconds.
circuit.
compound

If

When

These

Be

careful

the

plug,

remove

or

unclamp

clean each plug's

solution

too

way

prod

body

or out of the

the

plugs

get

the.plugs don't

reinstalling

on

examine

much,

to

to

the

of the

ohm

drain

very

the

threads.

to
replace

test

glow

resistance.

(13

in

the

hot

glow

not

the

each

remove

the

tip

glow

plug's

glow

engine.

amps

engine
(at

the

heat

the

glow

ENGINE

plugs

will

become

to

burn

your

electtical tenninal

plug

from

the

tip

and

threads

all

the

carbon

for

wear

and

the

plug.

plugs

is

with

an

wire

connection,

plug,

as

shown. A good

This

method

You

can

also

per

plug).
and

test them

tenninal

up

quickly,

plugs,

end)

check

use

very

fingers

connections,

cylinder

with

a soft

and

oil

bum

erosion;

ohmmeter.

can

be

use

an

again.

within 5 to

for a short

anti-seize

ADJUSTMENTS

GLOW

PLUG

hot

when

head.

brush

deposits.

and

the

glow

used

with

annneter

The

if

plug

10

it

to

,..-....lL----""'----

.

TIGHTENING

2.0

-2.5

TORQUE

m-kg

USING

TEST

LIGHT

(14.5

-18.0

TESTING
AN

OHMMETER

A

ff·lb)'

WITH

ON

.

• .

CONNECTION

:TlP

A

CAUTION:

30

seconds.

Do

not

ke~pgi~

GLOW

REFER
DIAGRAM
MANUAL
WIRING

plug

PLUGS

TO

THE

WIRING

IN

THIS

FOR

ALL

CONNECTIONS

on

for

more

than

+

-...v-

WESTERBEKE

Engines & Generators

24

NOTE:

ments

be

below

is

ENGINE

WESTERBEKE

peifonned by a competent

provided

to

ADJUSTMENTS

recommends

assist

the

that

engine

mechanic.

the

following

mechanic.

engine

The

infonnation

adjust·

CHECKING

Valve

is cold

1. Remove the head cover.

2.

Align the
on the housing so that the No.1 piston comes to the
compression or overlap top dead center.

3. Check the following valve clearance (1) marked with

-!:<

4.

If

adjust with the adjusting screw.

VALVE

The

TC

There is

piston comes to the top dead center position when the
marking is aligned with the projection in the window on
the flywheel-housing. Tum the flywheel
clockwise and counterclockwise to see
the compression top dead center
Now, referring to the table below, readjust the valve
clearance.

IN.

the

position when both the valves move.

Finally, tum the flywheel 6.28 radius
TC

marking and the projection perfectly. Adjust all the other

valve clearances
After turning the flywheel counterclockwise twice

times, recheck the valve clearance.

After adjusting the valve clearance, finnly tighten the locknut

of

the adjusting screw.

VALVE

clearance

ITC

using a feeler gauge.

the clearance

CLEARANCE

marking line on the flywheel is

no

TC

The

and EX. valves do not move.

CLEARANCE

must

be

checked

mark line on the flywheel and projection

is

not within the factory specification,

0.23·

marking for the other cylinders. The No.1

piston is at the top dead center when both

as

required.

and adjusted

0.27mm

when

(0.0091

·0.0106in)

just

for the

0.26 radius (15')

if

the piston is at

or

the overlap position.

It

is at the overlap

(360') and align the

engine

No.1

or

three

TC

PROJECTION

1

ITG

MARK

o

TIMING

WINDOW

\ \

FLYWHEEL

\1

/

.

FLYWHEEL

jHOUSING

Adjustable
cylinder
location

When No.1 pistop is
compression top dead

center

, ,

When
overlap position

01

piston

No.1 piston is

Valve, arrangement

IN.

No.1
No.2
No.3
No.4
No.1
No.2

No.3
No.4

"*

"*

"*

"*

4CYL.

EX;

"*

*
"*

"*

I-

Engines & Generators

ADJUSTING
SCREWS,

LOCKNUT

25

r-:"'''''''''''~IIiI~

'0

~'a,

U'

VALVE

CLEARANCE

0.23·

0.27mm

(0.0091

·0.010610)

NOTE:

ments

be

below

is

TESTING

To
install a mechanical

warming
the oil pressure

OIL

LOW

, The specific safe

ualloss of oil
additional information on low

ENGINE chart.

OIL

OIL

test

the

oil

up

the

PRESSURE

GALLERY

WILL

OIL

PRESSURE

pressure

PRESSURE

pressure,

remove

oil

pressure gauge in it's place. After

engine,

set the engine speed at idle and

gauge.

RANGE

BETWEEN

minimum

oil pressure

usually indicates worn bearings. For

the

oil pressure sender,

50

AND

oil

pressure readings, see

ENGINE

WESTERBEKE

pe/formed

provided

55PSI

is

MECHANICAL

OIL

by

to

assist

AT

1800

5 -

10

psi. A

PRESSURE

ADJUSTMENTS

recommends
a competent engine

the

then

read

RPM

grad-

the

GAUGE

that the following engine

mechanic.

mechanic.

.
.

TESTING
COMPRESSION

.

COMPRESSION

626

psi

ALLOWABLE

472

psi

NOTE:

cause

INJECTORS. Poor fuel quality, contaminates and loss

positive fuel pressure

injector faults.

When re-installing the

DRIVE

-

-33.2

In

may be fuel injector

adjust-

The

information

COMPRESSION

ADAPTER", .

ENGINE·

'..

PRESSURE

44

Kgf!crtf

-4.32

LIMIT

AT

250

Kgf!crtf

-3.26

case

of

severe vibrations and detonation

BELT

ADJUSTMENT

TESTER

.f-

.'

""

.

""'~~INJECTOR

~

AT

250

Mpa

RPM

Mpa

problems,

to

the injection

glow

plugs

i""",,'".

.

GLOW

RPM

see

FUEL

pump

will

use

anti-seize compound,

PLUG

noise,

result·

DR

HOLE

the

of

in

DlL

GALLEIiY

ENGINE

Check tile compression pressure.
remove all fuel injectors, or glow plugs, disconnect

shut-off solenoid
the injector hole or
tester on the adapter
motor until the pressure reaches a maximum value. Repeat

this

dramaticaliy (at least

average of
by

If
is
for the weak
cylinder is still

cylinder to
comes up -

Abnonnally high readings
carbon accumulations,

accompanied

COMPRESSION

wire,

process for

more than

a weak cylinder
either valve

each

the

others.

35.5

or

piston related. Check the valve clearances

cylinder,

low,

seal

the

the

rings

by

high

To

do

this warm the engine,

the

and

install a compression adapter in

glow

plug hole. Connect a compression

'and

crank the engine with

cylinder. Look

20%) lower compression than

Compression pressure should not differ

psi

(2.5

kg/cm'). at 280 rpm.

is

flaaked

adjust

apply

a small amount

rings and repeat

are

faulty.

:on

Ii

condition that might be

pressures

for

by

healthy cylinder, the problem

as

needed and test again.

the

all cylinders indicates

and

noise.

tl10

starter

cylinders with

the

of

oil into

test.

If

compression

the

heavy

fuel

If

the

Excessive drive belt tension can cause rapid wear of the

and reduce the service life
A slack belt or the presence
slipping, resulting in high operating temperatures.

The drive belt is

deflected
inch (12mm)
mfdpoint between the
belt. A spare belt or belts should

A

WARNING:

drive

belt's

Adjusting

1. Loosen

2. Loosen the alternator adjusting bolt.

3. With the altemator loose, swing it outward until the
belt is tensioned correctly.

4. Tighten both bolts.

5. Check the tension again after

operation.

·properly

no

less than

as

the

tenSion

Belt

Tension

the

alternator pivot bolt.

of

the fresh water pump's

of

oil

on

the

belt can cause belt

adjusted

3/8

inch

belt is depressed with the thumb

two

pulleys

Never

attempt

while

(IOmm)

the

if

the

belt can be

and no more than

on

the

longest span

always

be carried on

to

check

engine

is

in

the

engine has been in

or

adjust

operation.

bearing.

at

board.

the

belt

the

of

drive

112

the

.

Englne_s

26

&.Generators

ADJUSTING

BOLT

TACHOMETER

TACHOMETER/HOUR

The tachometerlhour meter used in propulsion engine
instrument panels contains
with a common ground.
and the other the tachometer. The hour meter circuit operates
on

12

volts alternator charging voltage supplied to

tenninal
The

from one of the diodes
tachometer input tenninal while the engine
the alternator producing battery charging voltage 13.0-14.8
volts

The following are procedures to follow when troubleshoot­ing a fault in either of the two circuits in a

meter.

Hour

Check for the proper DC voltage between (+)
tenninals.

1.

2. Voltage not present - trace

Tachometer

Check for the proper AC voltage between tachometer input

tenninal and

1. Voltage present - attempt adjusting meter through

2.

3. Check for AC voltage at tach tenninal on alternator

4. Check electrical connections from tachometer input

Tachometer

1. Check for proper

2. Check for good ground connection between meter

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

Tachometer

a. Using a hand held strobe tachometer reading front crank

b.

c. Using a

on

the back of the instrument.

tachometer circuit operates

DC.

Meter

Voltage present - meter

connections forfault. (Jump 12 volts DC
tenninal to verify the operation.)

Inoperative

Inoperative

(-)

tenninal with the engine running.

calibration access hole. No results, repair or replace

meter.

AC

voltage not present - check for proper alternator

output voltage.

ground.

to

terminal

alternator connection.

Sticking

tenninal and (-) terminal.

tenninal and alternator.

alternator pivot bolt.

Inaccurate

shaft pulley speed. Adjust the engine speed to
engine rpm

Using the coars adjustment, select A, B, 4,
puts the panel tachometer rpm reading the closest to the

strobes tachometers rpm reading.

pod

strobe tachometers rpm.

..

5164

on

the panel tachometer to read the sarne

METER

two

separate electrical circuits

One circuit operates the hour meter

the

(+)

on

AC voltage

in

the alternator and supplied

is

defective - repair or replace.

(+) and (-) electrical

AC

voltage between "tach inp."

(2mm).allen wrench, adjust the calibration

6-8

volts, fed

to

the

is

running, and

tachometerlhour

and

(-)

to

meter (+)

DC

to

(-)

112

rated

6,

or 8 that

as

the

WESTERBS

Engines &

COARSE

ADJUSTMENT

TACHOMETER

NDTE:

In

the

tachometer
engine's
installations.

1. Warm up the engine to normal operating temperature.

2.

3. Aim the light of the tachometer onto the reflecting tape

4. Set the tachometer to the idle speed (the engine

rpm.

Remove any specks on the crankshaft pulley with a clean

cloth and place a piece of suitable reflecting tape

pulley

Start and idle the engine.

to confirm the engine speed. Check the instrument panel
tachometer reading. Adjust the tachometer
by using the instrument coarse adjustment to calibrate the
instrument reading to the closest rpm that the photo tach
is

showing. Then use the fine calibration adjustment

bring the instrument to the exact reading

tach.

has been factory adjusted and the idle screws and high

speed screws have been locked in place).

•

~

:1

-

-

-~

r

-~------------------------

Gen.erator

CHECK

a new installation having new instrument panels,

may

This

to

facilitate use of a photoelectric type tachometer.

-

-

!

•

-

- - - - -

OIL

PR

••

~

;~

'f

~

,

..

mi~ITt~

" I

(New

Installation)

not always

calibration should be checked

;fo

,:::..=-

S.

be

0,0

~

g •

•

;

-

-

vmR

~G~UU[

correcJly

------

calibrated

in

as

-

-

0~

UR[~<

III

<

K

vou~mR

I

[D

. "

eu@

~

~

"-~"',,7

III

REO

''"'1!'i

SlUT

5WlTCH

IIU

ED

'UDU~

II~

iLK

the photo

TERMINAL

in

all

on

the panel

idle'

I

;

-

- -

®

P~['SlART

to

the

new

the

to

speed

~

-

27

The

following

relating

lems,

and

troubleshooting

to

engine

service,

the

recommendations

the

probable

table

to

overcome

ENGINE

describes

causes

certain
of

these

these

TROUBLESHOOTING

problems

prob-

problems.

NOTE:

The
ampere
the

back

the

same

engine's

manual

of

the

bracket.

electrical

reset

engine.

circuit

The

system

breaker

preheat

is

protected

located

solenoid

by a 20

on a

is

mounted

bracket

at

on

Problem

No

panel

indications;

or

fuel

pump

and

PREHEAT

button

button

OK;

soienoid

cranks,

fuei

solenoid

,

can't

be

runs

not

charging

is

no!functioning,

down.

is

on

START

engagement.

START
indications
fuel

Engine

start,

Engine

Battery

Battery

fuel

not

working

button

is

depressed,

is

depressed;

starter

solenoid

but

dOBS

energized.

stopped.

solenoid

(key

is

depressed).

no

starter

panel

OK;

not

switch

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

Preheat

2.

Low

battery

3.

1.

Faulty

DC

Disconnect

2.

Fuel

run

3.

Oil

pressure

1.

High

resistance

2.

3.

Low

resistance

Poor

battery

4.

5.

DC

alternator

(tachometer
DC

charge

1.

2.

Alternator

switch

not

circuit

breaker

breaker

solenoid

connections,

soienoid

to

soienoid

not

in

connections.

fuel

solenoid.

system.

solenoid

power.

alternator.

fuei

solenoid

switch.

connections.

not

not

circuit

drive.

Cause

on.

tripped.

tripped

on

not

operating.

faulty.

neutral.

to

fuel

solenoid.

fauity.

shut-off

cabie.

will

not

leak

to

ground.

ieak.

charging.

opereting).

faulty.

de-energize.

1.

Check

2.

Reset

circuit

3.

Check
preheat

4.

Check
engine

5.

Check

1.

Check

2.

Gear

HURTH

3.

Check

4.

Check

Check

5.

6.

Check
Check

1.

2.

Check
fuel

1.

Check

1 ••

Check

1b.

Fuei

fuei

2.

Check

3.

Switch

3 ••

Replace

Remove

1.

2.

Check
offthe

3.

Manually
solenoid

Observe

1.
.

is

2.

Check

lines.
after

Check

3.

Check

4.

corrosion

Check

5.

DC

1.

Pertorm

Testing

2.

Check
for
voits

Verificatlon)Remedy

switch

and/or

battery

breaker;

if

and
the

(+)

solenoid
connection.

shift

switch
that

that

run

filters

system.

not

short

ELECTRICAL

loose

breaker

check

circuit

voltage

both

solenoid.

connection

ground

must

HSW

12
battery
battelY
connections.

12

solenoid.

that

fuel

for

air

clogged.

solenoid.

to

combine

batteries.

EXG,

connection

fuel

disconnect

althe

if

gauges

running.

wiring.

(Do

not

all

wires

cable

connections,

DC

the

drive

connections.

are

present

to

stUd.

Check

"S"

terminal

be

in

neutral

TRANSMISSIONS).

with

ohmmeter.

volts

are
connections.
charge

state.

volts

are

vaives

in

fuei

system.
Repiace

house

connection

at

shut-off

the

injection

and

Test

the

Insert

sensitive

start

engine.)

Is

located.

for

temperature

connections

check

SYSTEM/ALTERNATOR.

voltage

check

Baftel)!

Charging

belt

tension;

at

the

connections.

trips

again,

for

shorts

at

and

after

starter

battery

for

(see

present

present

are

open.

Bleed
filters

and

start

at

alternator;

lever.

12

volt

pump.

panel

lights

oil

pressure

Remove

at

battery

belt

of

Circuit.

alternator

Check

Exc.

terminal.

check

to

ground.

the

breaker

solenoid

cable

voltage.

NEUTRAL

at

the

solenoid

at

the

(+)

air

from

and

bleed

batteries.

repair

Pull

connection

are

activated

switc~.

(0 -.25

amp)

connections

rise

to

locate

for

loose

tension,

should

output

with

preheat

solenoid

on

the

and

(-)

connection

connections.

SW/TCHunder

connection.

connection

lever

test

charging

voltmeter.

on

fuel

system.

air

from

alternator.

back

to

close

to

the

fuel

when

meter

in

battery

and

the

fauit.

connections,

altemator.

circuit.

turn

freely.

Ensure

to

the

run

engine

replace

See

See

Check

12

(continued)

Engines, & Generators

28

ENGINE

TROUBLESHOOTING

Engine

Engine

Engine

I

Engine

Exhaust

Problem

slows

and

stops.

overheats/shuts

alarm

sound

alarm

sounds

smoke

down.

pulsales.

continuously.

problems

".

1.

Fuel

2.

Switches
or

disconnected.

3.

Fuel

4.

20

Amp

Exhaust

5.

6.

Water

.

Air

Intake

7.

Raw

1.

2.

Coolant

1.

Loss

2.

011

pressure

Engine

1.

High

2.
too

Blue

1.

2.

White

Black

3.

Probable

11ft

pump

failure.

and/or

starvation.

circuit

breaker

system

In

fuel.

obstruction.

water

not

circulating.

not

circulating.

of

all.

switch.

coolant.

temperature

Iowa

temperature.

smoke.

smoke.

smoke.

Cause

wiring

loose

tripping.

is

restricted.

switch

opens

at

.Verilication/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-

2.

Obstruction

2a.

Thermostat -remove

2b.

20.
2d.

1.

2.

1.

.

2.

1.

la.

2.
2a.
S.
3a.

3b.

3

3d.

••

high

breaker

tripping.

for

blockage,

elbow.

watarfrom

fuel

system

air

Intake

Raw

water

pump

Replace

thermostat.

Loss

of

coolant -check

for

leaks.

Broken

or

loose

Air

leak

In

bleed
Check

all
Replace
Check
Check

check

system;

air.

Add

dipstick,

drein

hose

all
engine
for

satisfactmy

wllh

Incorrecl

grade

Crankcase
through

Engine
Faulty

Improper
Fuel

Insufficient
exhaust

Improperly

ventilation.

Is

the

Is

running

injeelor

grade

bum

incomplete

system;

Lack

of

air -check

Overload.

make a distinct

for

short

for

proper

fuel

valves,

DC

amperage

Is

not

overly

collapsed

fuel

tank(s);

.

failure.

at

raw

water

belts

-

run

coolant

as

look

for

conneelion.

pressure

swllch.

coolant

level.

of

engine

overtilled

eXhaust).

cold.

or

Incorreci

of

fuel.

due

for

proper

check

timed

injectors

air

operation

ohmmeter,

air

circuits

Check
Intake

and

hoses,

t~hlen/replace.

engine

needed.

all

replace

oil.

with

combustion

air

Intake

ticking

and

loose

operation.

fuel

11ft

pump.

draw

during

sensitive

to

heat

hose,

carbon

change

filters

impeller -replace.
or

raw

water

test

In

hot

water.

hose

clamps,

and

open

the

leaks

at

all

filter

wllh

switch

If

faulty.

engine

all

(oil

injector

timing.

to

high

back-pressure

valves,

(check

or

poor

Intake).

or

sound.

Replace

connections.

operation.

Which

would

buildup

at

and

fnter.

drain

plug,

prassure

tap

and

at

bypassed,

Is

blowing

out

in

exhaust

for

reslrlctlons

compreSSion

.

Check

for

proper

etc.

to

or

In

.

Engines & Generators

29

NOTE:

77w

located

CONTROL

MANUAL

engille

011

the

STARTER

cOlltml

ellgine

as

PANEL

system

is

close

as

possible

TROUBLESHOOTING

DISCONNECT

pmtected

to

the

by a 20

(TOGGLE

amp

power

source.

manual

SWITCHES)

reset

circuit

breaker

Problem

PREHEAT

fuel

preheat

START
engagement.

NO

NOT

BATTERY

depressed,

solenoid,

solenoid

SWITCH

IGNITION,

CHARGING

RUNS

no

electric

panel

fuel

pump

not

energized.

DEPRESSED,

cranks,

does

not

BATTERY

DOWN

indications

and

no

starter

start.

Oil

Pressure

1.

2.

20

amp

K2

relay

3.
Connection

1.
Faulty

2.
3

..

Faulty

Loose

4.

Low

5

"

K1

relay.

6.

Faulty

1.
Check

2.
Faulty

3.

Faulty

1.

Oil

pressure

1.

2.

High

Low

3.

Faulty

4.

Probable

switch.

circuit

breaker

faulty.

to

solenoid

switch.
solenoid.

battery

connections.

battery.

fueling

system.

for

air

in

the

fuel

lift

pump.

alternator

switch.

resistance

resistance

alternator.

Cause

fuel

drive.

leak

to

leak

to

tripped.

faulty.

system.

ground.

ground.

1.

Check

2.

Reset
circuit

3.

Check

1.

Check

2.

Check

3.

Check

4.

Check
Check

5.

6.

Check

1.

Check

2.

Allow

3.

Replace

1.

Check

turns

output
regulator

Observe

1.

engine

2.

Check
lines
after

Check

3.

4.

After a good
If

leakage

replace.

VerificationlRemedy

switches

andlor

battery

breaker.

If

it

run

circuit

with

12

yolts
connections.
charge

fuel.

to

bleed.

lift

pump.

drive

belt

Check

terminal.

the

gauges

not

running.

Wiring.

Insert

NOT

start

is

located.

wires

for

battery

stops.

Remove

opens

for

ohmmeter.

are

present

state.

and

for

loose

Ensure

and
Test

sensitive

engine).

temperature

charging,

and
relay.

connection.

switch

that

battery

battery
relay.

for

system

fuel

the

freely.

with a voltmeter.

if

is

the

(Do

short

all

connections.

again,

check

shorts

to

at

the

its

tension.

connections.

12V

panel

lights

the

011

pressure

(0-.25

Remove

rise

disconnect

alternator

preheat

ground.

solenoid

Be

sure

the

Check

are

present

are

activated

switch.

amp)

meter

connections

to

locate

the

alternator

and

bench

test.

solenoid

connection.

alternator

the

at

the

when

the

in

battery

and

replace

fault.

at

output.

Repair

or

If

the

gauge

reading

by

the

gauge

when

step

is

to

check for

and

tile

Negative (B-) tenninals of the

Assuming that tilere

TROUBLESHOOTING

is

other than what

the

instrument panel

12

volts

DC between

is

12

volts

as

required, leave the

WATER

is

nonnally indicated

is

energized, the

the

ignition (B+)

gauge.

instrument panel energized and perfonn the following

1.

Disconnect

gauge

reads

tile

sender wire at the gauge

zero,

which

is

the nmmal reading for tins

and

see if the

situation.

2.

Remove
gauge
scale,

the

wire attached to tile sender tenninal at

and

connect it

wInch

is

to

ground. See if

the nmmal reading for

the

gauge reads

tlrls

situation.

~

TEMPERATURE

first

AND

If

both of

undoubtedly OK and the problem lies eitiler

conductor

If

either of the above gauge tests are negative,

probably defective and should be replaced.

steps:

Assuming

to

sender
Check

th&t

Some starters have isolated

the

full

battery

is
tennhlals),
to

tile

block.

WESTERBEKE

Engines

-$i--Generators

30

OIL

PRESSURE

the

above gauge tests are positive,

from

the sender

the

gauge

is

the

sender tenninal

the

engine block

GAUGES

to

tile

gauge or

OK,

check tile conductor

at

tile

is

connected

ground

colmected

the

to

tile starter (both plus

ground side

will

not

the
witll

Witil

gauge

for

to

the

tel'minals

and

necessalily

gauge

the

the

sender.

tile

gauge

from

the

continuity.

ground.

and

if

tile

minus

be

connected

is

is

ALTERNATORS

NOTE:

FOR

CORRECT

REFER

TESTING/TROUBLESHOOTING

SEE

WIRING

DIAGRAM

WIRE

CONNECTIONS

-~~5'i~

WIRING
WIRING

TO

FOR

TO

THE

OPTIONAL

EXCITER

TERMINAL

.J!

ALTERNATORS

HARNESS

DIAGRAMS

CONNECTIONS

IN

THIS

TO

THE

MANUAL.

ALTERNATOR,

DESCRIPTION

The following
that

are

and Marine

ELECTRICAL

The charging

regulator,

and a battery
the use of integrated circuits
regulator
back of

It

is

desirable to
voltage
electrical
In-boat testing
operational test of

components of

ALTERNATOR

111e

stator
rectifier
converts
battery
lights,

refrigerator,

Power

alternator
package

These

alternators
Rated output
rpm

at

alternators are

range of

information

supplied

Generators.

CHARGING

system

an

engine

with

is

very

the

alternator.

regulator)

loads

that

will

the

is

connected

package

the

AC

charging

to

the

regulator

is

provided

contained

is

an

ambient

designed

_40°

to

with

WESTERBEKE'S Marine Engines

consists of an alternator

DC

wiring harness, a

connecting cable and

compact

test

the

charging system (alternator and

in the boat using the wiling harness and

are

a permanent part of the

then

provide the technician with

the

charging system

electrical

DESCRIPTION

to a three-phase, full-wave bridge

which

contains six diodes. The bridge
generated in the stator
and

accessories such

depth

sounder,

and

by

the

in

the

alternator.

produce a rated output of

achieved

212'P

at approximately 6000 'altemator

temperature

to

(-40°

applies

to

the standard alternators

CIRCUIT

with

a voltage

DC

circuit breaker

wires.

Because of

(Ie's), the electronic voltage

and

is

mounted internally

system.

as

well

as

the major

system.

to. a DC

as

etc.

the

field

of the integral regulator

field diode (or diode trio)

of

75°P (23.8°C). The

operate

to

100°C).

in

an

output for

a radio, heater,

50

or

51

ambient temperature

or

on

an

amps.

the

VOLTAGE

The

integral
device
the

voltage

system

The regulator
thick-fihn
adjusted
encapsulated
possible

.

encountered

ALTERNATOR

Use

this

exists

with
determined
have

a qualified

LOW

BATTERY/FAULTY

If

the

starter

of

spinning

faulty

connection in
problem.

A

simple

the

light

the

light remains

statting circuit.

A

alternator
alternator

REGULATOR

voltage

regulator

which

senses

the

system

applied

voltage.

assembly

to

the

damage

to

the

field

design

utilizes

techniques.

proper regulating

to

protect

the circuit

due

to

handling

in a vessel.

TROUBLESHOOTING

troubleshooting section

the

charging

that

the

only

the

engine

test

is

to

dims

significantly

WARNING:

can
until

circuit or

alternator

technician

moans

to

the

starting circuit

try statting

bright,

look for a poor connection

A

working

become

it

has

cooled.

or

life it

very

is

an

electronic

voltage

in

all-silicon

or

checbt.

order

After

value,

and

or

vibration

to

determine

with

voltage

level

to

maintain a proper

semi

the

voltage

the

the

components

the

regulator

CIRCUIT

makes a clicking

is

likely a low

and

again

with

a cabin

or

goes

out,

the

alternator

hot.

Do

runs

not

switching

and

switches

conductors

has

been

entire circuit

and

moisture

if

a

problem

alternator.

sound

not

battery

touch

is

battery

an

alternator

light

is

hot.

'a

the

If

faulty,

insiead

dead.

in

and
is

from

it

is

or

a

on, if
the

failed

If

,.

WESTERBEKE

¥'!fl~,!e_s

31

&

G~,?_erators

ALTERNATORS

TESTlNG/TROUBLESHOOTlNG

PRELIMINARY

Before starting the
testing

the

1:

Make certiun

2.

Check
if it

is

3. Check that all

tight.

and
resistance
undercharging
corroded battery
reaching a

4. Check the
necessary. A low
or

misleading

NOTE:

An isolator with a

selector switch

the batteries

along with the hause batteries.

the starting battery but not the house

alternator

charging

INSPECTION

actual

following

your

the

drive

worn

or

glazed.

terminals,

loose

or

and

this

or

cables

fully

charged

condition

readings

is

so

the

is

Ok

and

circuit.

alternator

checks

are

alternator

belt

for

proper

connectors

corroded

could

cause

damage

or

usually nwunted in

to

could

condition.

of the battery

discharged

on

Ihe

diode,

starting battery is not discharged

the problem

and

voltage

regulator,

recommended.

is

securely

tension.

connections

overcharging,

the

charging

prevent

battery

in-vessel

a sole/wid, or a battery

If

mounted.

Replace

and

plugs

cause

system.

the

battery

and

charge

may

tests.

the

circuit

the isolator

battery,

is

in

the

battery

cause false

is

the

the

belt

are

clean

high

Badly

from

if

to

isolate

c!ul.rging

3.

111m

Ensure

connections

4.

If

a

ensure

5.

111m

engine.

6.

Check
condition,

off the engine.

Ihat

the

are

battery

selector

Ihat

it is

on

the ignition switch, but

the

battery

Ihe

battery

tight

switch

on

Ihe

voltage.

reading

Inspect

and

all

terminals

clean.

is

in

correct

If

Ihe

should

wiring

and

connections.

and

the engine ground

the charging circuit,

setting.

do

not

start

battery

is

in good

be

12

to

13

volts.

MEASURING

BATTERY

(IGNITION

ENGINE

the

VOLTAGE

ON

OFF)

TESTING

A

certain

away

1. Start the engine.

2. After

THE

ALTERNATOR

CAUTION:

that

from

Ihe
starting battery voltage
multimeter

a.

If

Ihe
alternator is
directly

b.

If

Ihe
exists
continue

Before

everyone

sheaves

engine

set

on

voltage

working;

to

"Checking

voltage remains

wilh

eilher

with

starting

is

clear

of

and

belts

during

has run

is

Steps 31hrough

for a few

at

Ihe

battery

DC

volts.

increasing toward

omit

Steps 3 through 8 and

Ihe

Servic~

around

Ihe

alternator or

the

engine

moving

test

minutes,

terminals

14

Battery".

12

volts,

Ihe

8.

make

parts!

Keep

procedures.

measure the

using a

volts,

Ihe

a problem

charging

circuit;

go

Testing

1.

2. Wiggle the engine wiring harness while observing the

3. Start the engine.

4.

5. If the previous test

The

Output

Connect the positive probe
connect the negative probe
the

alternator.

voltmeter. The meter should indicate the approximate
battery voltage,

obtained,
output circuit for loose or
damaged

Repeat the
the positive probe
voltage reading should be between

If

repaired at a reliable service shop.

terminal B use the meter

terminal. If
R,
Jump
battery)

13-14

or
wiring.

sarne

your alternator is over

12

inspect the wiring for breaks and poor connections.

12

volts

and

volts,

Circuit

to

the output terminal

to

the gronnd terminal E

and

should

not

vary.

If

no

if the reading varies, check the alternator

dirty

connections or

measurement, the negative probe

to

B wilh the engine running. The

13.5

and

or

under-charging, have it

reads

only

battery voltage at

to

volts

from a 12

operate

then

Ihe

measure the

is

not present at exciter terminal

volt source (such

the

alternator.

alternator

is

DC

If

voltage output

OK.

reading

14.5

excitation

as

the

Band

is

to

volts.

on

E,

is

MEASURING

BATTERY
VOLTAGE

ENGINE

RUNNING

"'IIY'"

WESTERBEKE

Eng!ne~

_~_

Gener~t~rs

32

ALTERNATORS

TESTING

OUTPUT

ENGINE

TESTING/TROUBLESHOOTING

THE

CIRCUIT

RUNNING

TO

STARTER

SOLENOID

5.

If

no reading
alternator-excitation lead or in the excitation circuit
the regulator. Disconnect the lead from exc. terminal
Connect the positive multimeter probe to the excitation
lead and the negative multimeter probe to ground
terminal

approximate battery voltage, the voltage regulator
defective and must be replaced. If
indicated, check the excitation circuit for loose
connections

is

obtained, an open exists in the

E.

If

the

or

damaged wiring.

multimeter now indicates an

no

voltage is

or

of

R.

is

dirty

.

BATTERY

TESTING

THE

EXCITATION

CIRCUIT

1. Connect the positive (+) multimeter probe to the

excitation tenninal R on the alternator and the negative
(-) probe to the ground terminal E on the alternator.

2.

'furn

the ignition switch

the multimeter The reading should be

2.5

volts (see

3.

If

the reading

rotor

field

4.

If

the reading

field circuit probably is open.

is

between .75

circuit probably

is

between 6.0

to

the

on

position and note

and

1.1 volts, the

is

shorted or grounded.

and

7.0 volts, the rotor

EXCITER

TERMINAL

GROUND

TERMINAL

1.3

to

CHECKING

Check the voltage of the service
have
running.

charging circuit. Troubleshoot the service battery charging
circuit by checking the wiring and connections, the solenoid,
isolator, battery

When

is

back in operation, take the time
tenninal
wiring

ALTERNATOR

If

tests indicate a
disassembled and
shop

NOTE:

instructions for
standard

BATTERY

The minimum recommended capacity of the battery

the

engine's 12

Cranking
Review the manufacturer's recommendations

establish a systematic maintenance schedule for your
engine's starting batteries

• Monitor your voltmeter for proper charging during

engine

• Check the electrolyte level and specific gravity
hydrometer.

• Use
level.

ii

Make certain that battery cable connections are

tight

THE

SERVICE

a voltage between

If

not,

there

switch,

the problem

studs.

Also

13

and

is

a problem

and

has

been solved

clean the connecting terminals from the

harness.,

REPAIR

failed

altemator, it

repaired.

can

do

the job.

WESTERBEKE'S Service

the

altem.ators.

Any good allemator service

disassembly and

CARE

volt

DC

control circuit

Amps

(CCA).

and

operation.

only

distilled water to bring electrolytes

to

the battery posts (and to your

BATTERY

battery.

14

the battery itself.

house batteries.

This battery should

volts

when the engine

in

the

service battery

and

before the alternator

to

tighten and clean

will

need

ManuallUlS

repair

is

600-900 Cold

engine).

to

detailed

of

their

and

be

then

with

to

a proper

the

used

clean

is

in

a

and

~

WESTERBEKE

Engines & Generators

33

DESCRIPTION

Dual

output

and

high

output
optional
alternators
add-on

Dual
batteries
charge

equipment

can

equipment

alternators

at

the

each

set

on

most

be

installed

at

anytime.

can

be

configured

same

time

of batteries

INSTALLATION

If

an

optional

simply

engine

If

the

the-boat"
instructions

1.

Disconnect

battery.

2.

Remove
output

3.

Install

4.

Attach a new
alternator's output tenninal
indicated.

dual alternator

follow

the

installation

new

dual

engine,

below:

the

[positive]

the

new

WESTERBEKE

instructions.

alternator

carefully

the

alternators

alternator

cable.

alternator.

heavy

alternators

WESTERBEKE

during

factory

to

charge

or,

using a battery

separately.

has

already

wiring

is

being

added

follow

the

negative

and

disconnect or tape off

Do

not

reuse.

gauge

output

cable[s]

[s].

Using

DUAL

are

available

engines.

assembly

two banks of

selector

been

factory

diagram

to

an

existing

alternator

cable

the

installation

from

from

cable

OUTPUT

as

These

or

as

switch,

TO

installed,

and

the

"in-

the

the

the

sizes

ALTERNATORS

.

SPACER
BRACKET

DUAL

OUTPUT

[CHARGING

ONE

TO

MOUNTING

ALTERNATOR

BATIERy]

[ALWAYS

5.

Make

cable

the

positive

6.

Mount
location.

a.

Connect

alternator.

A

CAUTION:

out

first

h.

Plug

certain

c.

The red
the

d.

The

which

to

a switched [+]12 volt

WESTERBEKE

connection.

Dual

Pulleys

A

variety

charging

dealer.

USE

FINE

STRAND

certain that

to

the

engine

cable.

the

regulator to a flat

the

black

Do

grounding

the

2-pin

connector

it

is

firmly

"battery

batteries positive

brown

wire

actuates

CABLE]

the

batteries

block

is

wire

to

not

connect

the

regulator.

seated.

sense" wire should

[+]

"keyed ignition"

the

regulator.

WIRING

of accessory pulleys for

alternators

are

available

negative

the

same

surface

in

the

ground

any

power

into

the

alternator,

post

[or

the

is

this

wire

source.

Refer

DIAGRAM

high

powered

from

your

post

heavy

a cool

tenninal

be

connected

positive

the

must

to

for

I

ground

gauge

dry

on

source

make

cable].

key

circuit

connect

the

the

proper

and

dual

as

the

with-

to

BATTERY

TO

11.---:::::::::=::::::---.

~=="BATTERY

""";:!ID,...

.

TO

BATTERY

KCONNECTS
.

BLUE

'2-,WI,QECCINNECTS

DUAL

LEADS.

.

WIRE

CONNECTS

OIL

PRESSURE

OUTPUT

[CHARGING

SENSE"

POSITIVE

POST

TO

PINK

AND

THE

PINK

TO

BUZZER.

THE

THE

BLUE

.TO

THE

SWITCH,

ALTERNATOR

TWO

BATTERIES]

~

WESTERBEKE

Engines & Generators

34

DUAL

OUTPUT

ALTERNATORS

TROUBLESHOOTING

NOTE:

Bejore

troubleshooting,

belts

are

tight

and

the

batteries

Regulator

The red "battery sensing" wire A connects to the battery, it

must always read battery voltage.

present,

The orange
volts [approximately] with the key on.

incorrect,

The blue wire F supplies current to the alternator fields, its
voltage
load/rpm. The readings can vary from 4 to
key

KEY

ON • NO

KEY

OFF·

REGULATOR
Terminal/Color

I

Brown

A

Red

S

Orange

F

Blu.

All.

Testing

trace

the

wire

for a bad

wire

S should read 0 volts with the key off, 12

trace

the

wire

will

vary depending on the battery charge or actual

on,

0 volts with the key off.

VOLTAGE

BATIERY

VOLTAGE

TEST

POINTS

AND

Ignition

on

o

volts

12.6

volts

o

volts

o

volts

Output

12.6

volts

make certain

are

in

If

connection.

for a bad

REGULATOR

.

connection.

IS

REGULATOR

PROPER

VOLTAGE

Ignition

On

2

-12

volts

12

volts

o

volts

10

-11

volts 4 -12

12

volts

that

the

drive

good

condition.

battery voltage is not

If

the readings are

12

volts with the

DEFECTIVE

IS

DEFECTIVE

Engine

Running

14.2

volts

14.2

volts

6-8volts

volts

14.2

volts

Alternator

The

regulator

are

in

1. Test the voltage at the alternator plug with the
off-key on. The voltage at the alternator
the voltage in the plug
should read the same.

2. Hold a screw driver close

If

.not, the problem may

[open circuit].

3. Start the engine, at fast idle the output tenninals should

indicate 14.2 volts [no load]. A reading
indicate the alternator is not performing properly.

Apply a load such
should maintain at least 13.8 volts.
indicates the alternator is faulty.

Testing

is

functioning

good condition.

voltage

is

present you should feel the magnetic field.

properly

[blue wire F] from the regulator

[1/2"] to the alternator pulley.

be

the brushes [worn]

as

an electric bilge pump, the voltage

and

13

volts

the

batteries

engine

tenninal

or

of

12.6 would

or

the rotor

less

F and

NOTES:

o

When

the

engine

is

first

jar

the

is a noticeable

.

RPM

gauge

o A slight

on

the

alternator

change

will

whine

is

alternator.

to

"kick in" and

in

excite.

normal

started,

.

the

sound

when

it

takes

take

oj

the engine and

running

a few

the

load.

with

moments

There

a full load

If

the

o

o

When

the

become
When

replacing

purchase

alternator

very

hot.

and

replace

is

the

alternator

producing

dual

belts

high

drive

in

amperage,

belts,

matched

always

pairs.

it

will

Engines & Generators

35

HIGH

OUTPUT

ALTERNATORS

DESCRIPTION

Dual output and high
optional equipment

alternators can be installed
add-on equipment at

Dual aiternators can be
batteries at

the

charge each set of batteries

same

output

on

most

anytime.

configured

time

alternators

WESTERBEKE

during

factory assembly or

to charge

or,

using

a battery selector switch,

separately.

INSTALLATION

~f

an

optio~al

mstalled,
and the engine installation instructions.

If

the

new
the-boat" engine, carefully
instructions below:

1. Disconnect the

tery.

2. Remove the alternator

output [positive]

3. Install the

4. Attach a

alternator's output
indicated.

LENGTH

[ALWAYS

dual alternator

SImply

follow

dual alternator

alternators

cable.

new

alternator.

new

heavy gauge output cabler

REQUIRED

USE

FINE

has

already been

the

WESTERBEKE wiring diagram

is

being

added to

follow

the alternator

negative cable from

and

disconnect or

Do

not reuse.

terminal

UP
UPT012'

UP

STRAND

TO

TO

[s].

6'

20'

CABLE]

Using the

#4
#2
#0

are available

engines.

two

an

tape

s]

cable

WIRE
WIRE
WIRE

#14
IGNIflONB+

as

These

as

banks

of

factory

existing "in-

and

regulator

the

bat-

off

the

from

the

sizes

8WE/114

PINK,

5. Make certain that
to

the

engIne block

the

batteries

is

positive cable.

6.

Mount the regulator to a flat surface
a, Connect the black

wires

alternator (ground)

A

CAUTION:

witllout

h.

and

c.

The red "battery sense"
batteries positive

II.

which actuates the
to

first

Plug

the 2-pin connector

make

The

brown wire "keyed ignition"

a switched [+]12 volt source. Such

Do

grounding

certain it

[+]

regulator,

pressure switch.

e.

A brown wire

from

the regulator.

Dual

Pulleys

A

variety

of

accessory pulleys for high powered and

charging alternators

are

available

dealer.

114

BROWN

the

not

is

post

same

fmnly

negative

heavy

to

the

connect

tile

regulator.

into

seated.

wire

[or

post ground

gauge

as the

in

a cool

dry

location.

mounting bolt on the

any

power

source

the alternator connection

should be connected

the

positive cable].

is

the key circuit

this

wire

must connect

as

the oil

the electric tachometer connects

dual

from

your WESTERBEKE

BALMIIR

114

100

liMP

BLACK/GROUND

ALTERNIIToR

cable

to

the

to

14

RED

TO

STARTING'

BATTERY

Sf

USING

#14

BWE/#14

PINK

IGNITION~B+~~C::::i~",

.#14

BROWN

WHITE

WHEN

TWO

BATTERIES

#14BROW/v"

TACHOMETER

MALE

CONNECTOR

THJSSIDE\

."'"

+-++++-~'

r

D D

D

,

#4

REO

TO

BATTERYB'iJW;iHiETiN:R'1

USING

TWO

---

--~?f)))}]

WESTERBEKE

Engines & Generators

#t4RED

.

SENSE

1188ROWN

NOTUSED

#14

WHITE

STATOR

#14

BLUE

FIELD

STARTING

'ES';~'''==~~J;~~~

36

[DESCRIPTION

irhe

starter

is a new
N.gh-speed
separate
binion

~haft

pxposed outside the starter

smoothly without
botor

[ever

breidentical to

intemal-reduction

from

shaft.

and

a pinion

shaft

is

mechanism,

type,

the

motor

A reduction

shaft.

becoming

supported

switch

conventional

shaft;

The pinion

at

small,

starter.

the

gear

is

so

that

fouled

both

and

overrunning

ones.

light-weight

The

pinion

pinion

slides

installed

ends

sliding

the

with

on

between

pinion

dust
ball

clutch

STARTER

and

is

called a

shaft

is

only

on

the

the

motor

part is

not

may

slide

and

grease.

The

bearings.

inner

The
circuit

MOTOR

IGNITION
TERMINAL

~""'---I(M)

TERMINAL

TERMINALS"--~

MOTOR

SOLENOID

TYPICAL

STARTER

REFER
DIAGRAM

MOTOR

TO

THE

IN

WIRING

THIS

MANUAL

~ROUBLESHOOTING

"A

WARNING:

procedures
Sparks

could

Prior to testing,
charge

and

that
(terminals)
,\he

ground wire

tro

check

~econds,

hand
that indicate

Using a

temlinal stud
(ground).

If

yon read 12 volts, the starter

are

the

never

along

the

multimeter,

The

must

not

cause

make
the

starting system

clean

and

connections

wiring,

try cranking the starter for a

more

than

wires

and

resistance.

test the voltage

on

the

start solenoid

following

be

used

an

explosion

certain

tight.

10

terminals

Repair

emergency

with

gasoline

and

the

ships

batteries

wiring

Pay

particular attention

on

the

engine

seconds

or

replace

is

at a time,

looking

between

and

the

fanIly.

fire.

connections

block.

for

any

the positive

engine block

starting

engines_

are

at

full

few

tilen

run

warm

spots

trouble

spots.

to

your

To

test

the

ignition

of

is one
circuit).
from
terminal

If

circnit.

If

motor is fanIty.

If

current..

wiring

defective.

the

Use a screwdriver,

that

ignition

on

the starter cranks, the fanIt lies with the ignition

the solenoid clicks but nothing happens, the

SOLENOID

IGNITION

nothing happens

Check

connections.

circuit, locate the ignition(s) terminal (it

small

the

solenoid.

terminal

terminal

the

studs

and is wired to the ignition

don't touch the blade, to jump

to

the positive battery connection

at

all, the solenoid is not gettiog

battery

isolation switch and inspect the

it

is

also

possible that

the

. "

-~

solenoid is

starter

POSITIVE

A

fly

when
space
gasoline,
materials

Engines & Generators

37

WARNING:

jumping

is

free

of

and

that

stored

There

terminals.

potentially

there

nearby.

will

be

Be

explosive

are

arching

certain

NO

flammable

and

sparks

the

engine

fumes,

solvents

will

especially

or

STARTER

MOTOR

A

WARNING:

position

the

engine

other

crew

iGNITION

TERMINAL

Test

again
screwdriver
screwdriver
would

cause a

When

performing

yourself

by jumping the

safely

away

in

case

the

engine

members

blade finnly between the

blade

short.

of

to

touch the

the

danger.

J-i'<"'----\IYIITERMINAL

two

large terminal

solenoid

these

from

the

moving

.starts-up.

studs.

or starter

procedures,

parts

Also

warn

POSITIVE

studs.

Hold

Do

not

allow

casing,

of

the

the

this

EMERGENCY

Corrosion

can

cause

but

time
will

need

It

is

however,

starter

lightly with a

With

the

starter/solenoid

to

the starter

the

sporadic

not

another.

to

be rebuilt

battery

START

If

sometimes

small

switch

casing

brushes

problem

corrosion

possible

hammer.

off

and

as

shown,

andlor

of the

is

the

to

no

ignition,.

then

the solenoid

engine

starting one

problem,

get

started by

tap lightly

to

start

contacts

the starter

taping

on

the

engine.

the

the

A

WARNING:

starting
the

If
If
Ifno

solenoid.

NOTE:

In

that
using
will
starter switch
it

will

thaugh

current

screwdriver.

the starter spins, the solenoid is faulty.
the starter fails to spin, the motor is probably faulty.

arching occurred, there is

Starter

the

pre-engaged

engages

a screwdriver

run

the

create

the

contacts inside

There

will

be

arching

should

be

flowing

motors

are

either inertia type or

model,

the

the

starter motor

to

bypass

motor without

on

to

enoughmagneticfieldfor the

provide

engaging

power

the

thru

no

juice reaching the

solenoid also moves

to

the

flywheel

the

solenoid

the

to

the

solenoid

as

the

the

blade

of

on

flywheel.

solenoid.

arm

are

bad.

full

pre-engaged.

an

the

such

Tum

Hopefully

to

move

of

arm

engine.

a starter

the

even

If

that

fails, turn the
member
with
contact
the

turn the iguition

the

hammer.,

to

start the

starter will need

battery

This

engine.

to

be

SERVICE

WESTERBEKE
serviced
center,

If

certified
USCG
dealer.

TO

1.

2.

3. Label and disconnect

4. Remove

5.

or rebuilt

replacing

for marine

standards.

REMOVE

Disconnect the

If

necessary,

to

the starter

allow

wires

Remove the starter

starter will bave
obstructions,

uses a standard

at

the starter

use.

If

in

FOR

SERVICE

negative

remove

motor.

to

touch,

the

starter

to

any

motor,

be

switch

on

and

may

loosen

When

repaired.

starter

make

Automotive

doubt,

contact

battery

any

components

the

wiring

tape

over
mounting
from

the

mmed

on

and

have a

off

rapidly

the

brushes

you

reach a repair

starter

motor

motor

automotive

certain

starters

your

WESTERBEKE

cable.

to

from

the

the

terminals).

bolts.

engine.

In

some

to a different

as

you

and

which

the

new

do

not

gain full

starter.

cases

angle

tap

again

allow

facility,

can

service

motor

meet

access

(Do

the

to

clear

be

is

not

"'IIY"

WES,ERBEKE

Engines &-Generators

38

ZF

MARINE

TRANSMISSIONS

INITIAL

All
the engine
the

Fill

(DEXRON
up
just

into

not

Check

also

hoses,

VENT~--I':;~

OPERATION

ZF

marine

transmissions

at

the

fluid

is

drained

the

gearbox

II

or

to

the

index

insert

the

dipstick,

the

case

after

forget

the

sealing

for

leaks

make a visual

and

shift

with

mark

and

cables.

I

.

11\1

'1

l~

"

FLUID

DRAIN

.

1

FLUID

Change
operation,
year

Removing

Push a
the bottom
allows,
from
drain
washer.
the used

or

the

into

recheck

CHANGE

the

fluid

then

every

when

you

the

suction

pump

of

the

use

the

tranSmission

bottom of

a container,

Wipe

down

fluid.

After

the

fluid

factory

prior

before

shipment.

Automatic

DEXTRON

on

the

do

not

the

fluid

level

ring

under

change

inspection

1

for

the

first

250

operating

change

engine

fluid

hose

down

housiag

leveL

and

the

transmission

then

the

transmission

running

reinstall

are

test-run

to

delivery.

Transmission Fluid

III).

dipstick.

screw

is
the

the

fluid

ofthe coupling,

FLUID

time

suck

drain).

the

engine,

on a

test

For

safety

The

fluid

level

To

check

it

in.

Screw

checked

after

oiL

through the dipstick hole

and

hexhead

after

hours

out
Remove the drain plug

and

the

of

the

first

oil

KEEP
OPENING

LEVEL

about

25

or

at

the

fluid.

allow

plug

with

and properly dispose of

shut down

stand

with

reasons

should

the

fluid

level,

the

dipstick
tighten.
the

VENT

least once a

the

dipstick.

25

hours,

cooler

CLEAR

hours of

(If

space

fluid

its

sealing

and

Do

and

be

to

to

LOCKING

Locking
required:
direction

the

in
boat.

WHEN

Rotation

is

being

operation of
charging

transmission

DAILY

o Check

o

THE

PROPELLER

of

the

propeller

use

the

gear shift lever

of

travel

for

position

corresponding

UNDER

of

sailed,

SAIL

the

propeller without

being

the

engine

the

battery),

OPERATION

the

transmission

Visually

check

the

shaft

by

an

additional

position

this

purpose.

OR

towed,

with

will

have

gear

BEING

Never

to

the

direction

TOWED

load,

or

anchored

the propeller stopped (for

no

detrimental effects

fluid.
shift linkage

opposite

such

in

and

o Start the engine in neutral, allowing a

idle to

warm

the

fluid.

o Shift

NOTE:

from

the

For
Transmission

MAINTENANCE
TROUBLESHOOTING.

General

Gear

No1e:

of

Only a few
Fliud

(approximale)

Lubricating
Propeller

DIrection

into

Too

the

transmission

idle

speed

adrlitional

ZF

TRANSMISSIONS

Ratio

There

are a variety

gear

ratios

are

Quantities

Shall

01

gear.

Iowan

idle

speed

gear

and

should

be

increased

iaformation refer to

Section:

(optional)

available.

listed.

Fluid

Rotation

SHAFT

AND

TRANSMISSION

(ZF

hardened
servo-operated

ZF
ZF
ZF

ZF
ZF
ZF

ATF -Type A or

Right-hand
listed.

Standard

25M
25MA
30M

25M -1.58
25MA
30M -1.90

will

produce

damper.plate.

the

following

COUPUNGS,

SPECIFICATIONS

Transmission)

helical

gears,

multiple

(1.88:1

or

(2.22:1

or

(2.14:1)

pints

-1.58

pints

pints

Dextron

rotation

brake

is

not

your

put

the

gear shift

of

travel of

as

when

a'river.

transmission.

few

a chattering noise

In such cases

text

with

disc

2.27:1

or

2.73:1)

(0.75

litres)

(0.75

(0.90

litres)

-

II

lor

above

the

the

boat

as

well

on

minutes at

in

this

Case

a

clutch

2.73:1)

litres)

or

III

models

as

the

DRAIN

PLUG

TORQUE

NOTE:

When

changing

drain

plug

sealing

this

sealing

washer.

A

WARNING:

engine

Is

running.

dipstick

hole.

20 -2511/1bs

washer.

Never

Hot

This

could

the

fluid,

The

pullout

fluid

cause

take

care

drain

plug will leak without

the

dipstick

wIll

splash

severe

not to

while

from

the

burns.

lose

the

the

Engines & Generators

39

DESCRIPTION

The infonnation below

tlie

TRANSMISSION

applies

to

all

models.

CONNECTION

HBW recommend a

transmission gearbox and

flexibly

deflections.
bearing
taken
specified under

However,

additional
torsional vibration.
certain

Even

coupling or "ORNESAVER" will reduce
gearbox
wooden boats or
output

mounted,

The installation

is

not required,

by

the

transmission

the output

loads.

to

observe the manufacturers instructions.

with

the engine

bearings

flange

and stem

is

specific

TROUBLESHOOTING

OF

GEAR

BOX

WITH

flexible

connection between the

the

propeller shaft

in

order

to

compensate for angular

of

a special propeller thrust

since

the propeller thrust will be

bearing,

SPECIFICATIONS

shaft

should be protected from

Special care should

When

using a universal joint shaft,

solidly

mounted,

caused

by bull distortions, especially

where

the distance between transmission .

gland

is less

INCLINATION

to

the

proyided

is

not

be

the

.than

ZF

MARINE

ZF

Transnrlssions,

SECTION

PROPELLER

if

the engine

the

value

exceeded.

taken

to prevent

make

use

of

flexible

stress

in the

in

about

800mm.

TRANSMISSIONS

NOTE:

When

is

installing
shifting
Bowden
sheaves,
support for shift control

threaded holes located

gear

CONTROL

The transmission is suitable

Upon loosening the retaining
be
(cable
not contact the actuating lever cover plate:

distance between lever and cover should be 0.5mrn.

The control

the
neutral
sbould coincide with the neutral position of

The shifting travel,
actuating
positions A
30mm for the inner pivot point

travel

is

not

impeded by

cable

or

too

small

housing.

Refer

CABLES

moved

to

any

or

rod

linkage). Make certain that the shift lever does

cable

actuating

A greater amount of shift lever travel
detrimental

which,
generation
by

slow

NOTE

position

lever,

is

shorter,

in

turn,

and

clutch

Check

shift lever

and

and

for proper

the

transmission,
restricted

rod

linkage,

a bending

cable

above

to

the

WESTERBEKE

position required for the control elements

or rod should be arranged

when

of

the

operating lever

as

measured at the pivot point of the

between the neutral position and end

B should be at least

is

recommended. However, if the lever

proper clutch engagement might

would

mean
clutch plate failure. This
engagement or

leve r travel

make

certain that

movability

by

unsuitably positioned guide

radius,

etc.

connections,

the

shift cover

for

single lever remote control.

screw,

the actuating lever can

in

the neutral position. The

on

35mm

is

premature

no

engagement at

at

least

OJ

In

order

use

the

on

top

parts

the

minimum

at

right angle

the

control console

this

lever.

for

the outer and

in

no

way

wear,

excessive heat

would

each

the
to mount a

list.

be

be

all.

season.

two

of

the

to

impeded

indicated

A

CAUTION:

the

actuating

shift

lever

travel

this

mechanism

transmission

The

position

lever

is

from

Is

in

any

warranty

of

the

mechanism

factory-adjusted

neutral

will

position

way

tampered

be

void.

to A and

to

ensure

with,

behInd

equal

B.

the

If

:-;,.,(;,;,.,,"0{-

CONTROL
CABLE

.

...•

O

FORWARD

A

FLUiD

SHIFT

LEVER

NE~RAL

REVERSE

B

o

ORAIN

_.

COVER

En!1ines

40

ItG!>JJllrator.s.

O.5mm

MINIMUM

F

DISTANCE

ZF

MARINE

TRANSMISSIONS

OPERATING

A

too

high,

transmission

Normal
should

A

maximum

reached
Make

certain

to

provide

TEMPERATURE

CAUTION:

stop

fluid.

operating

be

in

the

range of

temperature

for

a short

there

good

ventilation

TRANSMISSION

Coolers
and

The
prevents
fluid.
will,

leaks.

A

some
waters,

WESTERBEKE

TRANSMISSION

are

standard

the

ZF,30M,

cooler

is

any

possibilities

However,

in

time,

erode

transmission

circumstances,

maintenance,

a separate

the

cooler

If

the

fTansmission

the

engine

temperature

1220 F
of

time.

is

enough

and

COOLER

equipment

part

of

continued

the

inside

may

last ten years

depending

etc.

it

might.

recommends

fluid

immediately

of the

(500 C)

0

266

F (l30° C)

space around

cooling.

for

of the

coolant diluting

flow

of the cooler

on

having a

and

transmission

to

the

ZF-25M,

transmission

of coolant thm

or

operating

only

last half

spare

temperature

check

the

fluid

2120 F

(1000 C)

may

be

only

the

transmission

ZF-25MA

which

the

transmission

the

cooler

causing

more

hours,

cooler

external

bu~

tropical

that

time.

in

aboard.

is

MAINTENANCE

Transmission
housing
routine,

Periodically
and

corrosion.
checking
(fluid

..

Lay-up/Winlerize

Storage

o

Drain
with a proper

NOTE:

engine

o

cl~an

(use

o

Fill

prevent

months

o

Loosen
flange
removing
and

o

Inspect
Look

the
all

NOTE:

(twelve

fluid

before

For

maintenance

clean,

check

and

change
inspect

Make

the

fluid

level

will

appear

as

requires

heat

the

spray

condui~

moving

special

water

from

mixture

This

operation

raw

water

up

the

transmission

resistant

transmission

internal
or

more).

attaching

and

propeller shaft
the boat
with

the

gear

for

corrosion

and

parts.

If

the

trqnsmission

months

to

prevent

putting

the

- -

additional

ZF

Industries

Marine

US

3131

SW

Fort

Lauderdale, FL

Tel.:

(954)

Fax:

(954)

www.ZF~atin.l..COlIl

is

minimal.

the

fluid

level

as

the

fluid

every

300

the

transmission

certain

the air

vent

look

for

signs

strawberry

the transmission

cooling

paint).

corrosion

hardware

from

lubricant.

shift

of the

bending

or

more),

intimal

engine

inforniation conlac

Headquarters

42nd Street

581-4040
581-4077

cream).

care.

Follow

of

antifreeze

will

normally occur
system

and

touch

with

Dextron III ATFfluid

(extended

from

coupling

the

water.

cable,

linkage, and

end

fittings,

of

the

actuator roqs:Lubricate

is

to

be stored for.a

it

slwuld

corrosion.

back

into

3331:

Keep

part

operating

and

is

of

these proi;edures:

oil

coolant.'.

is properly

the transmission output

flange

Separate the

be

Reduceth,e

service

the exterior

of your regular

·hours.

the c()oler for leaks

cle~and

waterc(lnt8nnnation

coolerimd replace

up

unpainted

storage

cracks

topp~d

when

'When

the

winterized.

'areas

to

only,

twelve

hefore

flanges

.

attachments.

or

cuts

long

time

offwith

fluid.

in

level

Engines

41

& Generators

ZF

TRANSMISSIONS

(HSW

MODELS)

SHIPMENT

For

safety

reasons,
transmission
temporarily

Before

leaving
undergoes
The
draining
against

OIL

The
continuous
passes
overboard.
the

.

WESTERBEKE
HAVING A SPARE
ABOARD

RAW

CONNECTION

a test

residual

acts

corrosion

OUTPUT
COUPLlNG4

COOLER

oil

cooler,

through

The

tubes

and back into

WATER

TRANSMISSION

.Fill

the

transmission

should

be up

level,

press

Durlng

the

output

shaft and transmission cooler for

should

be changed

hours

thereafter.

NEUTRAL

These

transmissions

switch.

This is

Unless

the transmission selector lever

neutral,

the engine starter will not

the

transmission

fluid

during

attached

fluid

\

cooling for

to

the

WESTERBEKE

run,

with

remaining

as a preservative

for

at

__

...

mounted

the

the

tubes

transmission

RECOMMENDS

COOLER

FLUID

with

to

the

mark

the

dipstick

first

25

operating

after

SWITCH

are

to

prevent

is

not

shipment

the

actuating

Dextron

least

above

transmission

of

the

ZF

Dextron III

on

into

the

equipped

the

and

shaft.

plant,

III ATF

in

the

transmission

and provides protection

one

year if

the

transmission,

the

cooler

and

fluid

is

cooled

transmission.

COOLER

ATF.

the

dipstick.

the case

hours, inspect

first

engine

and

25

hours

with a neutral

from

is

activate.

filled

with

the

selector

each

transmission

properly

~--,AIR

flui,d.

discharges

After

tum

leakage.

and

starting in

perfectly

lever is

transmission

after

storro.

VENT

,

provides

Raw

water

as

it

flows

•

RAW

CONNECTION

The

fluid

checking

it

to

tighten.

the

bell

The

every 300

safety

aligned in

fluid.

ASSEMBLY

around

WATER

level

the

housing,

fluid

gear.

.

INITIAL

Set

and
with
shifting
forward
clutch
reversing

After

coupling,

the

LOCKING

Locking

required:
direction
the
boat.

WHEN

Rotation
boat is
well

.

(for
the

NOTE:

gear
idle

DAILY

o
o

q Start

o Shift

NOTE:

from

the

Operating

The
exceed
is
reach

OPERATION

tlie

shifting

let it

transmission

permits

initial

transmission.

ron

should

to

reverse

at

high

operation,

oil

lever

long

be

changing

cooler and

THE

of

the

propeller shaft

use

the

of travel

position corresponding

UNDER

of

the

propeller without a load,

being

sailed,

as

operation

charging

transmission.

shift

and

the

When

the

must

be

canfree-wheel.

OPERATION

Check

the

transmission

Visuaily

to

idle

the

warm

into

Too

Iowan

the

transmission

speed

check

engine

the

gear.

should

Temperature

operating

provided.

220°F

A

CAUTIOtJ:

too

high,

176°F

stop

(SO°C).

At

(104°C).

temperature of

transmission

NOTE:

Ensure

the

seasonally

will

fluid

cause

to

be

and

pressure

forced

to

neutral

position (N). Start·the engine

enough in idle

fluid.

Shift into

smooth

are

permissible since the

at

speeds in

make a

hoses,

and

high

the

to

fill

gear,

positive.

rpm

including

event of

visual

inspection

and

the

PROPELLER

by

an

additional

gear shift

for

SAIL

of

battery),

boat

in

fluid.

idle

maximum output of the

If

the

fluid.

transmission

clean

out

lever

position

tltis

purpose.

to

OR

BEING

being

towed

the engine

will

is

being

the

neutral

the gear shift linkage

in

neutral,

speed

gear

be

increased

A connection for a

the

transmission

engine

, . -.

with

carburetor

to

build

the

input

Never

the direction

TOWED

or

anchored

with

the

have

no

sailed

(engine

position.

fluid.

allowing a

will

produce a chattering

and

damper

the

transmission

immediately

vent

is

up

in

the

and/or shaft

the

cooler

and

forward

Direct

danger.

cable

detrimental

fluid

operational.

cleaner. A stuck

transmission

and

changes

multiple

sudden

of

connections

brake

opposite

put

the

gear

of

travel

such

as

when

in a

propeller

and

plate.

engine,

stopped

stopped),

The

propeller

transmission,

few

minutes

In

such

should

temperature

the

temperature

and

check

seals.

the output

your

of

river,

effects

and

hoses

reverse;

from

disc

to

is

not

shift
the

the

as

the

is

at

at

idle

noise

cases

not
probe

fluid

may

is

the

Remove

vent

cause

in

on

1~/WESTEilBEKE'

I

Engines & Generators

42

ZF

TRANSMISSIONS

(HSW

MODELS)

CHANGING

16MM ' SCREW

THE

DIPSTICK

TRANSMISSION

FLUID

FILTER

Replacing

Pour
with

Transmission

ers,

length

\

Reinsert
and

tighten the

NOTE:

screw

After

A

engine

h~le.

the

Fluid

in

new

Dextran

the

dipstick.

fluid

quantities will

of

hoses

and

Approximate

HSW450A2 ­HSW630Al-

the

filter

assembly

Allen

Some

ZF transmissions

on their filter

running

WARNING:

is

running.

This

the

englne,

could

assemblies.

Never

Hot

cause

III

ATF fluid

the angle of

2.65

U.S.Quarts

4.2

U.S.Quarts

into

screw.

shut

down

pullout

fluid

severe

and

vary

the

Quantities

the

housing.

use

a "T"

and

the

will

splash

burns.

check

the

with

the use

ttansmission.

(2.5

liters)

(4.0

liters)

Press it in

handle

recheck

dipstick

from

while
the

quantity

of

in

place

the

fluid

the

dipstick

cool-

place

of

level.

a

MAINTENANCE

Transmission

housing
routine,

PeriOdically

and

corrosion. Make cettain the air
checking
(fluid

maintenance

clean, check

and

change
inspect

the

fluid

will appear

is

minimal.

the

fluid level

the

fluid every

the

transmission

level look for

as

strawberry

as

300

and

vent

signs

cream).

part

of

Keep

the

exterior

of your regular

operating hours.

the

cooler

for

is

clear and

water

when

contamination

leaks

Filter

Elen~ent

The

ZF

transIllission
dipstick. This
changed

Remove the
a 6mm Allen

Twist

and

the

new

filter

it

clockwise. Check the O-rings for damage and replace

necessary.

WESTERBEKE

local

Removing

Pnsh a snction
the

filter)

to

Remove
to

Wipe.
fluid.

drain

down

the

into

PN#

049737

has a filter

filter

mnst be replaced whenever the

filter

by loosening

wrench.

pull out

Replacement

the

filter

onto

the

cover

dealer.

the

Fluid

pump

hose

the bottom of

oil

retum line

a container, then reconnect the oil retum line.

the

transmission

element located"opposite the

the

screw on the cover using

and

remove the element Place

and

lock it into place by turning

filters

can

be

obtained

down

through the

the

housing and suck out the

from

the

cooler

and

and

properly dispose of

from

pipe

allow

fluid

is

if

your

hole (under

fluid.

the

oil

the

nsed

Lay·up/Winterize

Storage

requires special care. Follow

[]

Drain water
with a proper mixture of antifreeze coolant

NOTE:

engine

o Clean

(use

heat resistant paint).

from

the

This

operation

raw

water cooling system

up

the

transmission and

transmission

will normally occur when

these

is

touch

o Fill the transmission with Dextron

prevent internal corrosion
months or

more).

o Loosen attaching hardware

flange and propeller shaft coupling

removing the boat

and

spray with lubricant.

o Inspect the gear shift cable,

for

Look
the conduit,

all

NOTE:

(twelve

fluid

before putting

corrosion of the end

and

moving

parts.

If

the

transmission

months

to

prevent internal

the

bending of the

or

engine back

from

more),

(extended

from

the

water.

linkage,

fittings,

actuator

is

to

be

it

should

corrosion.

into

the

storedfor a

procedures:

oil

cooler and

properly

up

III

storage

transmission

flange

Separate the

and

be
Reduce

service.

winterized.

unpainted

ATF fluid to

only,

before

attachments.

cracks or

rods.

topped off

the

replace

the

areas

twelve

output

flanges

cuts

in

Lubricate

long

time

with

fluid

level

Engines & Generators

43

TRANSMISSIONS

CABLE

The
Upon
illustration)
control

actuating
distance
(0.5mm).

The
to
neutral
should
transmission.

The

actuating
A
!-3/16in

CONNECTIONS

transmission

loosening

elements

lever

between

control

the

actuating

position

coincide

shifting

lever

and

B,

should

(30mm)

PROPELLE~"--"--

ROTATION'
A=RH

N·NEUTRAL

D=LH

can

does

cable

travel,

between

i

A.

is

the

be

(cable

the

lever

of
with

be

for

suitable
retaining

moved

or

not

lever

or

rod

when

the

gear

the

as

measured

at·

least

the

(HSW

for a single

screw,

to

any

rod

contact

and

should

in

shift

neutral

the

neutral

1-3/Sin

inner

linkage).

the

the

pivot

MODELS)

lever

the

actuating

position

the

be

neutral
lever
position of

.

at

B

Make

lever

hub

should

arranged

on

the

pivot

position

(35mm)

point.

reqnired

hub:

position.
the

gear

shift.

lever

certain

the

minimum

be

O.02in

at a right

The

control

the

lever

point

of the

and

end

for

the

N

'.

ACTUATING

'LEVER

----.

(see

for

the

that

angle

console

on

the

positions

outer

the

and

AOJUSTING

1.

Loosen
idle

2. Adjust

throttle
the

(800·

3.

Tighien

4.

Race
times
speed

ENGINE

POSITION
STOP

CONTROL

ENGINE

FUEL

The

optional

shut

down

solenoid

adjustme~t.

THE

IDLE

the

locknut

adjustment

the

engine

1000

the

to

remains

STOP

CABLE

DOWN.

SHUTOFF

has

bolt.

bolt

so

control

lever

at a quiet

RPM)

the

locknut.

engine

several

ensure

the

as

ADJUSTMENT

SO

WILL

SOLENOID

fuel

shutoff

using

the.instrument panel

been

fac;tory

THAT

SPEED

on

that

will

idle

idle

set.

THE

SHUT

the

the

hold

THE

solenoid

set

and

~::::l

allows

the

'engine

key

switch. The

does

not require

FUEL

'

SHUT·OFF

to

be

'i!~

n I r

.

A

greater

amount
detrimental
is

shorter,
which,
generation
by

slow

CONTROL CABLES

TROUBLESHOOTING)

NOTE:

and

proper

in

turn,

and

clutch

Check for proper actuating lever travel at least each

~CTUATING

~CHEGK

is

would

clutch
engagement

FOR

FROM

NEUTRAL

FORWARD

of

actuating

recommended.

clutch

engagement
mean
plate

under

LEVER;,

EQUAL

TRAVEL

THRU

AND

REVERSE

lever

travel

However,

might be

premature

failure.

or

no

TRANSMISSION

wear,

This

would

engagement

is

season.

A

CAUTION:

the

actuating

shift

lever

Ihls

mechanism

lransmission

lever

travel

wa"anty

The

position

Is

factory·adJusted

from

neutral

is

In

any

way

will

be

of

the

mechanism

pOSition
tampered

void.

to

to

with,

.

0.02

l=

.

(0.5MM)

in

no

way

if

the

lever travel

impeded

excessive

be indicated

at

all

behind

ensure

A

and

B.

the

IN

.

heat

(see

equal

If.

Engines &

SHAFT

WESTERBEKE
the
bly

The installation of a special propeller

required,

transmission

SPEC[FICATlONS

shaft
should
univers.al

turer's

Even
coupling
box
boats

coiIpling

NOTE:'When

shifting
or
small a
mount a support for shift control cable

the gear

G.s!1erators

COUPLINGS

recommends a flexible

transmission

mounted,

shduhf

be

inst:rq~~Ol1s.

with

bearings

or

rod

linkage,

two threaded

and

the

in

order

since

the

propeller thrust will be

bearing,

is

be

protected

taken

to prevent torsional

joint

shaft,

make

the

engine

or

"DRIVESAVER" will

caused

by

where

!he

distance between

and

stern.

gland

installing

is

not impeded

by

unsuit(lbly positioned guide

bending

radius

holes

located on

housing.

Refer

*DRIVESAYER

Rockland,MA.· -

propeller

to

compensate

provided

not

solidly

the

the

exceeded.

from

additional

certain

mounted

hull

distortions,

is

less than

transmission, make certain that

by

restricted movabiiity

or·

other restrictions.

the

to

the WESTERBEKE parts

is

connection

shaft

if the

for

angular

thrust

absorbed

value

specified

However,

loads.

vibration.

to

observe

the

use

reduce

stress

especially

the

transmission

about

800mm.

connections,

cable bracket mounted

a product

between

engine

deflections.

bearing

by

under

the

output

Special

When

the

manufac-

of a flexible

in

the

in

of

the

sheaves,

In

order

of

Globe

is

is

not

using

gear­wooden
output

cable

to

use
list,

flexi-

the

care

a

too

the

on

Marine,

43a

VELVET

DRIVE

TRANSMISSIONS

AIR

VfNT

.....

··r'<;;;:,y

FROM

t:1II111." _

CONNECTION

SHIPMENT

For

safety

reasons,
transmission
is

temporarily

Before

leaving
undergoes
fluid.
draining
against

a test

The

residual

acts

corrosion

TRANSMISSION

Check

the

transmission
transmission
continue
operation,
output
changed

300

A

NOTE:

seasonally
will cause pressure

jl~id

to

shaft

after

operating

CAUTION:

and

the

correct

starting

Ensure

to

be

the

keep

forced

the

fluid

during

attached

the

WESTERBEKE

run,

fluid

as a preservative.

for

FLUID

has

not

been

use

this

fluid.

a lookout for

and

transmission

the

first

hours

thereafter andlor

Be

size

engine.

the

transmission

and

clean

to

out

~~~v~~,~~

,

transmission

shipment and the selector lever

to

the actuating shaft.

with

Dextron

remaining in the transmission

at

least

fluid

filled,

During

25

hours

certain

cooler

with

carburetor

build

up

the

input

is

not filled

plant, each

III ATF transmission

and

provides protection

o~e

year

if

properly

level

on

the

dipstick.

fill

with

Dextron

the

first

25

hours of

any

leakage

cooler.

and

the

transmission

is

properly

vent

in the transmission and cause

and/or shaft

at

the

This

fluid

approximately

at

winter

instaffed

is

operational.

cleaner.

A stuck vent

seals.

OPTIONAL

REVERSE

PRESSURE

CONNECTION

TRANSMISSION

CLUTCH

GAUGE

•

WARNER

VELVET

DRIVE

TRANSlV!ISSION

with

transmission

after

stored.

If

the

III

and

bell

housing,

should

be

evelY

lay-up.

is filled

before

Remove

SHIFT

LEVER

The

gear

shift

ihe

actuating

(F),

Neutral

ball

located

to

center

the

the

helm

must
actuating
improperly
the
actuating
ensure

Shifting

Place
Shifting

tion
order.
speed.
allow

lever through

transmission.

lever

proper

Into

the

gear

from

may

be

Shifts

Start

the transmission

Neutral

Move

the

feel

the

detent.
mission.
completely

sion

NOTE:

switch.
aligned

does

Some

Unless

With

not turn.

in

Forward

Move

the

feel

the

detent.

the

forward

move

the boat in a

Reverse

Move

the

feel

the

detent.

the

reverse position.

should

move

NOTE:

Moving
Position·
always

the
engine!
of

gear

the

actuating

to

away

shift control

This

POSITION

control

lever

on

(N),

and

behind

the

lever

in

be

coordinated

adjusted

The

should

operation.

Gear

shift

in

one

selector

made

at

should

the

engine

gear

shift

TNs

the

control

interrupted

transmissions

the

transmission

neutral.

gear

gear

the

shift lever

The

position.

forward

shift

The

the boat

the

transmission

Forward

from

the

problem

lever

mechanism
the

transmission

Reverse

transmission

each

position.

shift

mechanism

shift

mechanism

shifting

be

free

Neutral

position

any

time

be

made

and

set

fluid

to

lever

to

centers

the

in

and

the

are

engine

to

actuating

The

output

direction.

lever

to

actuating

The

output

in a reverse

is

always

engine.

in

the

may

be a result

by

the

and

(R)

shifting

lever must

The

with

those

mechanism
of dirt

and

before

starting

to

below

1000

at the

lowest

the

throttle

warm

the

middle

actuating

this

position,

output

equipped

actuating

starter

the

forward

lever·

on

shaft

the reverse

lever

on

shaft

direction

actuating

toward

If boat

forward

position,

gear shift

linkage

can

another

up

w.ill

must

exactly

shaft

and

in

Forward

positions. A detent

work

gear

shift

of

the

Velvet

adjustments.

cause

damage

and

transmission

well

lubricated

the

engine.

selector

rpm

and

practical

at

idle

speed;

for a few

position.

w.ith

the

and

position.

the

the

moves

of

lever.

You

lever

on

hydraulic

of

the

a neutral

lever

is pelfectly

not

activate.

position.

transmission

the propeller

transmission
the

propeller

(astern).

lever

from

engine.

backwards

shut

incorrect

position

freely

positions

Drive

An

to
to

posi-

in

any

engine

minutes.

should

the

trans-

power

transmis-

safety

You

should

is

shaft

You

should

is

Neutral

Reverse

with

off

the

movement

at

is

in

in

is

"""

WESTERBEKE

Engines & Generators

44

fl4l:'''''l

FORWARD

,

TRANSMISSION

DAILY

o

Check

o

Visually

o

Start
for

NOTE:

noise
such

o

Shift

ACTUATING

OPERATION

the

transmission

check

the

gear

the

engine

in

neutral.

the

fluid

to

W81ID.

Too

Iowan

idle

from

the

transmission

cases

the

idle

speed

into

gear.

VELVET

n

NEUTRAL

LEVER

fluid.

shift linkage

Allow a

speed

will

gear and

should be

DRIVE

REVERSE

POSITIONS

and

transmission.

few

minutes

produce a chattering

damper

increased.

at

plate.

idle

In

TRANSMISSIONS

o

Clean

off

the

transmission

used

n

o

r

D

D

D

Oil

Approximately

sions

have a direct

will
angle
oil

fluid.

Refill

the
quantity
and

the

installation

Check

the

Replace
into

place

Run

the

A

WARNING:

engine

Is

running.

hole.

This

Capacity

to the

be

required

of installation

required

transmission

will

vary

dipstick

the

oil

filler

and

turn

engine,

could

oil

shutdown

Never

Hot

cause

2.5

quarts

level

fill

relationship

to

fill

will

to

fill

the

with

depending

angle.

for

the

cap

clockwise

pull

fluid

severe

(2.36

mark

to

the

oil.cooler

make

transmiSSion.

and

properly

DEXTRON

on

the

transmission model

Fill

through

proper

fluid

and

dipstick.

until

finger-tight.)

and

recheck the fluid

out

the

dipstick

will

splash

from

burns.

liters)

will

on

the

dipstick.

the

oil

capacity.

and

the

a difference in the

dispose

III

the
level.

(press the dipstick

fill

cooler

of

the

ATF.

The

dipstick

while
the

most

Many

Additional oil

hole.

level.

the

dipstick

transmis-

variables

lines.

The

quantity

of

°

A

CAUTION:

cause

damage
throttle
on

back

the

transmission

Shifting

to

to

idle

INSPECTION

o

Visually

Check

worn.

o

Lubricate

o

Inspect

o

Inspect

A

Sion
pOSitions.

CHANGING

After

changed

be
ter

haul-out.

becomes

o

Remove

o

Remove

drain

o

Reconnect

o

Use a suction

through

check

for

wear

the

detent

the

shift

the

transmission

CAUTION:

shift

lever

does

THE

the

initial

50

at

every

However,

contaminated,

the

oil

the

oil

into a container.

ti1e

the

filler

gears

above

1000

the

engine

damper

when

shifting

and

the

damper

for

oil

leaks

on

the

hydraulic lines

ball

and shift cable attachments.

linkage.

bolts; retorque if

Clutch

failure

not

fully

TRANSMISSION

hour

change,

300

operating hours thereafter

the

fluid

changes

filler

cap

and dipstick.

cooler

return line and

oil

cooler

re(um

pump

to

remove the transmission oil

cap/dipstick

plate.

gears

plate;

at the hydraulic connections.

will

occur

engage

the

FLUID

the transmission

must be changed whenever

color,

or

line.

hole.

rpm

Pufling

wiff

and

replace if

necessary.

if

the

detent

smells

allow

can

the

save

wear

transmis-

ball

fluid

or

at

rancid.

the

,,11

should

win-

to

it

D1PSTlCK

MAKE

O

----+:

CERTAIN

SEAL

Discontinue

panel

should

THE

IS

oil
230'F (1l0'C).

GAUGE

mechanical

fluid. A nOffi1a1

indicate

RUBBER
SCREWED
TlGHTTOTHE
HANDLE

Oil

Temperature

A

maximum
mended.
ture

exceeds

PRESSURE

An

optional

the

control
transmission
gear
constant.

temperature

operation

pressure

to

constantly

95 -120

FLUID

LEVEL

of 190'F (88'C)

anytime

monitor

reading

Ib-in'

gauge

at

(6.7 -8.4

sump

can

the

2000

pressure

is

oil

be

installed

rpm

kg-cm')

recom-

tempera-

of

in

forward

at

tl1e

and

be

Engines & Gimerators

45

VELVET

DRIVE

TRANSMISSIONS

MAINTENANCE

Transmission

housing
routine,

Periodically inspect
and

co'trosion.
checking
(fluid

Lay-upIWinterize

Storage requires

D Drain

replace

NOTE:

raw

D Clean

(use

D Fill

prevent internal

12

D Loosen attaching

output

removing the boat

and

D Inspect

Look
the conduit,

all moving parts.

maintenance

clean,

check

anq

change

Make

the.

fluid

will appear

special

the

water

it

with a

This

operation

water

cooling

up

the transmission

heat resistant

the

transmission with

months or

flange

spray with

the

gear shift cable,

for

corrosion of the end

and

the

the

fluid

the

transmission

certain

level

look

as

strawberry

care.

from

proper

system

paint).

corrosion.

more).

hardware

and

propeller shaft coupling flange

from

lubricant.

bending

is

minimal.

fluid

level

every 300 operating

the

for

Follow these procedures:

the

transmission

mixture of antifreeze coolant.

will usually occur when

is

and

Dextran

the

of

Keep

the

as

part of your regular

and

the cooler

air

vent

is

clear

sigus

of water contamination

cream).

oil

cooler

properly winterized.

touch-up unpainted

III ATF

(Extended storage

from

the

water.

Separate

linkage,

fittings,

the

actuator rods. Lubricate

fluid

transmission

and attachments

cracks or cuts

exterior

hours.

and

the

only,

the

for

leaks

when

and

engine

areas

to

before

flanges

..
in

WARRANTY

Service
dealer.

""Ivet Drive

on

its

gears
fully reversing of
Therefore torque loads

made at
caused

A

occur
resulting

Velcet
torsional

If

any

TRANSMISSION

NOTES

manuals

low

by

CAUTION:

at

problems occur with

are available

For assistance,

is

aware of

as

the

result of mechanical propeller operation or

the

engine

a shock load,

System·related

low

engine

in

damage

Drive

is

not

vibration

TROUBLESHOOTING

Velvet

1208
Liberty,
Tel.:

www.YelvetDrive.com

speeds.

from

your

BORG

WARNER

contact:

Drive

Transmissions

Old

Norris

Road

SC

29657

(800)

583-4327

.

the

shock

loads

that

can

be placed

propeller blades while shifting.

and

directional changes should be

If

it

is

found

that a failure

any

warranty claim will be denied.

noises

or

vibrations

speeds

responsible

of

to

this

the

type.

the

which

engine

can

cause

and/or

for

total

system-related

transmission,

in

gear

transmission.

see

this

manual.

was

can

rattle

NOTE:

if

the

transmission

(twelve months or

to

fluid

OIL

The continued

time,
occur.
following

1.

2.

Either

1.

2.

prevent

before

putting

COOLERS

erode

These internal cooler leaks will cause one of

two

Transmission

and

be discharged overboard through the engine

A loss

fail.

The

raw

ing

an

fluid

will

will eventually

case

Install a

Refill

the

internal

the

flow

the

inside of

problems:

fluid

of

transmission

water

will

increase

requires

in

appear

fail.

new

oil

cooler.

transmission with DEXIRON III ATF.

is

to

be stored for a long

more),

it should

corrosion.

engine

back

of

raw

water through

the

cooler causing cross leaks

will

leak

into

fluid

will

leak

into

the

transmission

as

strawberry cream.

an

immediate

into

the

cafA,se

transmission

fluid.

response:

be

topped offwith

Reduce

the

fluid

service.

the

cooler

flow

of

raw

the

transmission

This contaminated

The

transmission

time

will,

the

water

exhaust.

fluid

level

to

caus-

in

to

If

water

has

contaminated

needs

to

be cleaned

take

several

fluid

changes
Check your dipstick each time until it
mission
the

If

need

A

some

waters,
WESTERBEKE recommends having a

fluid.

Change

fluid

lines that connect

the transmission

the

attention of a qualified transmission service

transmission

circllffistances,

maintenance,

cooler

out

and

the

fails

to

may

depending

etc.

it

the

fluid,

the

replaced with

to

get

rid

of the contamination.

transmission

to

the

cooler.

shift properly, it

last

ten

years

on

operating

might

only

transmission

fresh

fluid.

appears

as

filter

and clean out

will

most likely

or

more

hours.

last half that

spare

cooler

fluid

It

will

pure trans-

facility.

but,

in

tropical

time.

aboard.

Engines & Generators

---.--

46

TRANSMISSION

TROUBLESHOOTING

(ZF

MODELS)

CONTROL

The

majority

CABLES

of
improper clutch
problems
rather

ZF

cable
If

shut
level,
the

neutral,
observe the
is stiff

and try

with

than

clutches,

adjustments.

you

experience

the

engine

then

full

range -from

into

to

operate,

again.

control

from

in

have a helper

full

actuating

If

excessively tight

Problem

Transmission
Fails

Transmission

but

fails

Delay

only

Transmission

Chattering

mainly

Boat

Oil

Leakage.

to

move

to

propel

of

gear

after

an

increase

transmission

at

low

fails

to

attain

gears

into

shifts

engagement

noise

engine

transmission

adjustments

cables

problems

particular,

operating

down.

First

move

neutral

reverse,

and

lever

break

the

it

is

still

stiff,

bends,

and

cannot

be

gear.

into

gear,

the

boat.

or

engages

in

speed.

becomes

louder.

noise,

speed.

specified

max.

difficulties

(manual

(hydraulic

with

are

very

problems

check

the

to

back

on

the

cable

check

check

shifted.

speed.

arise

transmissions)

transmissions)

the

transmission

sensitive

the

to

with

the

transmission-fluid

cockpit shift lever

full

forward,

to

neutral-

transmission.

loose

at

the

the

cable for

any

linkage for

1.

Actuating

2.

Shifting

unattached.

3.

Actuating

1.

Output

Propeller

2.

Output

Output

3.

propeller

Actuating

1.

equal

2.

Actuating

3.

Actuating

1.

Damage
to

wear

misalignment
transmission.

2.

Beginning

transmission

running

alignment

engine

1.

The

engine
vibrations
a

"chattering"

Operating

1.

Operating

2.

1.

CorroSion
Damaged

2.

Misalignment

as a result

or

itself.

improper

transmission,

through

back

to

while

you

If

the

remote

transmission

kinks

binding.

Probable

to N to

Cause

lever

is

cable

is

broken.

Cable

lever

is

coupling

is

shaft

is

coupling

is

coupling

shaft

are

lever

travel N to B not

A.

level

travel

lever

is

starting

or

fatigue.

between

damage

due

without

of

transmission,

output.

or

propeller

in

the

noise

temperature
without

at

radial

sealing

of

loose.

radius

binding

not

and

binding

on

to

fluid,

drive

output

of

or

bent

is

too

against

no\turning.

turning.

turning.

turning.

in

insufficient.

against

flexible

coupling

possibly

due

engine

of

bearings

torsional

overload.

or

generates

unit

which

in

the

transmission.

is

high.

cooling.

sealing

ring

ring.

flanges.

A

new
needed.
out

of

make

sure there's

If

the

transmission

have

a helper put it

the

propeller shaft; if
needs
thrust,
the

shaft
it isn't

NDTE:

immediately
authorized

or

severe.

the

cover

plate.

due

to

and

in

vibrations,

wrong

excessive

torsional

produces

and

shaft.

cable

and

While

the

geal'

using the

professional

check

to

see

or,

if

you

stuck

in the

If

you

suspect a major

contact

marine

Tighten

1.

Check

2.

Detach

3.

hand.

Transmission

1.

The

2.

on

the

pins
Inspect

3.

A

folding

propeller

1.

Adjust

See

Check

2.

DIAGRAM.

Check

3.

Check

1.

inspect

engine.

Transmission

2.

Mount a flexible

1.

between

a

higher

Inspect

2.

transmission.

1.

Wrong

Check

2.

Transmission

1.

2.

Check

perhaps a new

cable

is

lever

no

binding

passes

in

forward

the

attention.

you

still

linkage mechanism

loose,

shift

on

the

side

inside

these

tests,

and

shaft isn't

If it

does

have a

have a folding

"no

pitch"

position.

problem

your

WESTERBEKE

transmission

facility.

Verilicatlon/Remedy

damping

bolt

on

shifting

the

cable,

reattach

or

the

shift

cable
should

needs

bolts

are

Shaft.

bolts

may

be

in

plate

until

LEVER

cable

adjust

inspect

if

necessary.

needs

coupling

engine

factor

damper

Replace

of

fluid.

Inspect

needs

Must

and

be

professional

sheared

Tighten

as

It

may

be

"no

pitch"

the

TEXT

length.

if

plate

professional

and

transmission; a coupling

might

plate

if

Use

coolant

professional

be

Clearance

coupling

propeller

and

coupling

the

propeller.
propeller
may

cover

ACTUATING

shiff

lever

clearance,
alignment.

the

damper

Replace

the
stiffness

the

type

cooler.

alignment

the

transmission

of

the

transmission

the

case.

crank

the

engine

reverse

while

tuming,
propeller

or

the

tum

but there's

on

feathering

in

your

transmission,

dealer or

lever.

replace.

operate

the

in

(0.5mm).

attention.

or

the

or

replace

be

miSSing

position.

is

exact

AND

DIAGRAM.

See

ACTUATING

coupling.

the

attention.

another

be

suffiCient.

the

III.

hoses

attention.

0.003

actuating

coupling

set

or

mid-position.

transmission

stiffness

engine

check

and

coolant

in

0.02

necessary.

jammed. A variable

lever

necessary.

flexible

between

with

between

necessary.

Dextran

within

may

be

in

and
to

and

you

observe

transmission

no

the end of

propeller, that

an

lever

by

is

slipping

screws,

keys,

damaged.

pitch

LEVER

If

noise

persists.

and

the

factor

with

and

the

fluid

level.
flow.

(O.08mm).

~

WESTERBEKE

E,!9ines & Generators

47

TRANSMISSION

TROUBLESHOOTING

(ZF

MODELS)

Problem

Chattering

mainly

Transmission

but

transmission

at

low

fails

to

propel

engine

shifts

Problem

High

fluid

temperature.

Fluid

on

transmission

Fluid

and

water

Slow

engagement.

No

movement

of

speed.

into

the

boat.

housing.

mixed,

the

boat.

noise,

gear,

shifts

hard.

1.

The

engine

vibrations

a

"chattering"

1.

Oufput

2.

Propeller
Output

3.

Output
propeller

HSW

Fluid

1.

2.

Fluid

3.

Plugged
No

water

4.
Filter

5.

1.

Loose

2.

Loose

Loose

.

3.
Loose

4.
Fluid

5.
Oamage

1.
Selector

2.

Selector

1.

I.cw

fluid

2.
Unkage.

3.

Selector

1.

Improper

2.
Low

fluid

3.

Propeller

4.
Propeller

5.

Transmission

6.

Engine

7.

Probable

or

propeller

in

the

noise

coupling

shaft

is

coupling

coupling

shaft

are

Cause

generates

drive

unit

in

the

is

not

turning.

not

turning.

is

turning.

and

turning.

torsional

which

produces

transmission.

1.

Mount a flexible

between

a

higher

1.

Transmission

2.

The

coupling

on

the

pins

and

3.

Inspect
A

folding

propeller

TROUBLESHOOTING

Probable

level
level

clogged

fluid

level

Cause

high

during

low.

or

restricted

in

cooling

(if

applicable).

screws.
screw

connections.

dipstick.

filter.

high

during

to

fluid

cooler

control

linkage.

control.

level.

control.

selector

position.

level.

missing.

shaft

broken.

malfunction.

malfunction.

operation.

fluid

cooler.

system.

operation.
..

1.

Pump

2.

Add

3.

Replace

4.

Check

5.

Replace

1.

Tighten

2.

Tighten,

3 •

Tighten,

Tighten,

4.
Pump

5.

Replace

1.
Refer

2.
Refer

1.

Add

2.

Adjust

3.

Consult

1.

Adjust

2.
Add

3.
Replace.

4.

Contact

5.

Contact

6.

ContaCt

7.

fluid.

fluid.

fluid.

Verilicatlon/Remedy

coupling

the

transmission

stiffness

needs

bolts

propeller

coupling

the

propeller.

propeller

may

be

with

and

factor

might

professional

are

sheared

shaft.

Tighten

bolts

as

It

may

may

be

in

"no

pitch"

necessary.

be

jammed. A variable

Verllication/Remedy

out

fluid

to

the

maximum

cooler

and

flush

cooling

system

element.

to

specification.
replace.
replace.
replace.

out

fluid

cooler

this

manual.

this

manual.

(refer

this

service

(see

this

marine
manufacturer.
marine

and

to

the

maximum

and

flush

manual.

station.

manual).

repair.
repair.

water

repair.

transmission

another

stiffness

coupling

set

screws,

or

damaged.

on

on

and

hoses.

factor

with

is

slipping

pitch

dipstick.

dipstick.

engine. A coupling

be

sufficient.

attention.

or

the

or

replace

missing

position.

and

mark

system.

and

mark

keys,

NOTE:

If

you

suspect a major

marine

transmission facility

prt}Q.!em

..

·iWYour

transmission,

~

WESTERBEKE

Engines & Generators

immediately

48

contact your

WESTERBEKE

dealer or

an

authorized

SPECIFICATIONS

ENGINE

Engine

Type

Aspir~tlon

Compression
Governor

Combustion

Bore & Stroke
Piston
Hp@2800rpm
Firing

Inclination

Weight

Ratio

Chamber

Displacement

Order

(dry)

TUNE-UP

Compression

(allowable

Variation

cylinders

Injection

Engine

Valve

(engine

Injector

Valve

Starting
Battery
DC

Charging
Starter
Starting

DC

limit)

between

Timing

Speed

Clearance

cold)

Pressure

Timing

Battery

Capacity

Aid

Cranking

Pressure

(rpm)

Alternator

Current

SPECIFICATIONS

Diesel,

l!JUr-cycle,

water-cooled,

mechanism

Naturally

22.6:

Electronic

Swirl
98 x 110

3.31
65
1-3-4-2

Continuous

Temporary
730

1

type

liters

Ibs

(331

vertical

aspirated

mm

(3.86 x 4.93

(202.53

0

14

25°

(notto

kgs)

SPECIFICATIONS

626

psi

(44

(472

10%

13°
Idle -800 -1000

Cruise
Max. -2550 -2600

0.23 -0.27

(0.0091-0.0106

1991 -2134

Intake
Intake

Exhaust
Exhaust

ELECTRICAL

12-Volt

800 -1000
60

2.5Kw,
Glow
400 -600

kgf/cm')

psi

(30.5

or

less

BTDC

-1800 -2200

mm

Opens
Closes

Opens
Closes

DC

(-)
CCA

Amp

rated,

12

VDC

plugs,

(includes

kgflcm'l)

psi

14'

36°

45°

1 r

SYSTEM

negative

belt

direct

sheathed

four-cylinder,

in-line

overhead

inches)

cubic

inches)

exceed

at

250

rpm

in)

(140 -105

BTDC
ABDC

BBDC

ATDC

ground

driven

drive
type

glow

kgf/cm')

plugs)

tresh

10

limit

min.)

valve

General

Operating

Temperature

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

2600

rpm
Capacity

water)

Flow

Engine

The

inches

of

Injection
Injection

Nozzle

Filter

Intake

Flow

Combustion

Filter

Capacity

hot)

Grade

Elbow

Hose

Flow,

pressure

versus

water

Pump
Timing

oil

filter)

Oil

Pressure

Size

at

System
(fresh

Air

NOTE:-

compartment

2

General
Fuel

Fuel
Fuel
Injector
Fuel
Air

Air

General

Oil
Sump

(includes
Operating

(engine

Oil

Exhaust

Exhaust

COOLING

Fresh

water-cooled

thermostatically-controlled

160

-180° F (71 -82°

Centrifugal

Positive
gear-driven.

17.0

US

16.0

gpm

Cooling

(51

150

differential

the

inside

mm)

at

full

ctm

between

of

the

open

FUEL

Open

flow,

(electromagnetic

No.2

diesel

Bosch

type

13'

BTDC

Bosch

throttle

Spin-on

Metal

screenlintake

165

cfm

LUBRICATION

Pressure

Full

flow,

14.0

U.S.

28 -57

API

Specification

SAE

30,

EXHAUST

45°
3"

1.0.

SYSTEM

engine

C)

type,

metal

impeller,

displacement,

gpm

(15.1Ipm)

(4.2

the

engine

throttle

rubber

(41.6Ipm)

cmm)

outside

compartment

(measure

SYSTEM

self

bleeding

fuel

pump)

oil

(cetane

mini

pump

(spill)

type

type

silencer

(4.7

cmm)

SYSTEM

fed

system

with

paper

element,

qts

(13.2

liters)

psi

(2.0 -4.0

kg/cm')

CF

20W-40,

(76.2

or

15W-40

mm)

block,
with

heat

exchanger.

belt-driven

impeller,

of

the

engine

should

not

with a manometer)

-

se~

priming

rating

of

45

or

higher)

box

external

relief

spin-on

type

CG-4,

CF-4

or

CH-4

exceed

valve

NOTE:

Engine

Idle

Speed must
normal operating temperature.
in

the

range

specified

Different

model transmissions will affect engine

where

be

adjusted with the

Idle

speed should

it operates

the

engine

be

smoothest.

idle

at

adjusted

speeds.

Engines & Generalors

49

LAY-UP

&

RECOMMISSIONING

GENERAL

Many

owners

rely

on

their
including
off-season
to

The

own

check list if
These

during a

maintenance

If

your

provide

engines

accomplish

procedures

lay-up

procedures

lay-up

you

have

local

assistance.

Propeller

The transmission

opened

be

the

out of
storage
severe
the
shaft
apply

period of

in

strain

boat

is

has

actually

to

small

in

use,

not

time.

Fresh

Water

A

50-50

solution
recommended
This

solution

antifreeze,

solution
Should

amount

mixture.

and
cooling

to

more

from

Operate

mixture

system.

Lubrication

With

the

engine

sump.

Remove

with

new

ENGINE LUBRICATING

oil

changing

oil

pressure

A

CAUTION:

in

the

sump

combustion
chemicals

internal

and

or

for

long

lay-up

which

and

recommissioning,

others

do

should

and

also

needs

of

any

questions

servicing

Shaft

up
water
the

taken

unless

dealer;

Coupling

and

and

the

or

moved

cradle. The

on

the propeller

out or

been

boats that

they

.

Cooling

of

antifreeze

for use

may

require a

depending

make sure

antifreeze

the

engine

the

of

the

antifreeze

Now

System

warm,

and replace

oil.

Use the con"ct

procedure.

and

make

Do

over

the

deposits

which

can

parts.

generators,

periods

preparation

follow

the

your

propeller
bolts

in

on

the

engine

recheck

boatyards

procedures.

afford

help

engine.

regarding

he

to

for

lay-up

of

inactivity.

themselves.

will

allow

or

you

your

engine

familiarize

lay-up

will

be

more

prepare their craft,

Others

you

may

you

procedures, call

than

[Propulsion

half couplings

removed

from

flexibility

put

in

bent

are

have

been

by

when

land

to

water,

of

the

shaft

or coupling or both,

the

water.

In

these

strains.

hauled

out

of

dry

for

the

boat

some

the

a considerable

Circuit

and

distilled

the

coolant system

higher

concentration of

the

area's winter climate. Check

antifreeze

be

needed,

block

drain

Run

sure

not

lay-up

combine

reduce

drain

and add a more

to

ensure a complete

concentration

the

antifreeze

all

the

the

oil

filter

grade

OIL

pages

the

engine

there

are

leave

the

period.

to

the

water

protection

an

appropriate

throughout

solution's

engine

and

of

oil.

Refer

in

this

and

no

leaks.

engine's

Lubricating

produce

life

of

your

during

the

prefer

to

perform

use

them

protection

with

the

willing

Engine]

should

boat

is

and

during

often puts a

cases,

This

does

water when

is

at

all

times.

is

adequate.

concentrated

circulation

oil

from the

fill

the

sump

to

the

manual

check for

old

engine

oil

harmful

engine's

your

as

a

to

always

hauled

while

the

not

the

the

strength.

oil

for

the

proper

oil

and

Fuel

System

Top

off

or

higher. A fuel
stabilizer
gasoline/water separator
and

make certain there

fuel.

Fuel

System

Top

off your
additives
mix

with
Additives
should

be
condition
used

are

separator used

primary

sediment
Change

fuel

system,

for

5 - \0

system.
the

fuel
needed.
allow

movement

equipment

Raw

Water

Close

the

hose

from

gallon

bucket of clean fresh

the

check
the

engine

any

zinc

zinc

anode

Start

the

fresh

water through the

stop

the

solution slightly stronger

protection

Start

the
through
the

engine.

water

circuit

as

providing

Remove

antifreeze

Examine

a cover

until

recommissioning,

Cylinder

Spray

arrester
oil will

spark

[Gasoline]

your

fuel

tanks

conditioner

shOUld

be

added.

[Diesel]

fuel

tanks

should

be

added

the

fuel

being

such

as

Bio-bor

added

at

this time

the

fuel..

Care

compatible with

in

the

system.

fuel

filter/water separator

bowl.

the

fuel

filter

elements

as

needed.

minutes

Check

system
Operating the engine

on

for

during

of

the

engine.

to

any

the

make

Cooling

through-hull

the

seacock.

zinc

anode

and

clean or replace it

debris

from

inside

is

located.

engine

and

allow

engine

and

refill

in

your

area

engine

and

allow

the

raw

water

This

antifreeze

from

freezing

COlTosion

the

impeller

mixture

the

gasket.

will

impeller.

Do not replace

Lubrication[Gasoline]

fogging

plugs

oil

removed,

stall

out

for

into

while

the

engine

winter protection.

with

unleaded gasoline of 89 octane

such

as

Sta-Bil gasoline

Change

and

are

no

with

prior

added

and

should

the

Start

leaks
this

treated

the

element

clean

the

metal

bowl.

leaks.

Clean

up

No.

2D

diesel

fuel.

to

topping

and

Diesel

to

control bacteria growth and

be
primary
Change

and

on

the

engine

sure

no

that

may

servicing,

for

5 -

fuel

off

fuel

still

in

Kleen + Cetane Boost

taken

that

the

fuel

filter/water

the

element

clean

the

the

engine

and

allow

air

is

left

in

have

been
correcting them
10

minutes

through

the

Circuit

seacock.

Place

found

Clean

system.

protection.

from

accompany

Acquire a replacement, if

the

Remove

the

end

of

this

water.

Before starting

in

the

pr\mary

as

required,

the

heat exchanger where the

the

raw

water

the

raw

water

system.

but

the

bucket with

than

needed

all

of

mixture

during

your

replace

open

the

engine is

and

When

the

for

this

mixture

Once

the

should protect

the

winter

raw

water

it,

so

the

impeller

the

air

intake,

running.

coat

the

cover

the

raw

hose

heat

strainer.

pump

bucket

an

antifreeze

winter

bucket

pump

catch

(into

with

valves,

in

your

Re-install

any

spilled

Fuel

to

ensure they

the

tank.

additives

in

your

separator

and

bleed the

it

to

the

fuel

ereated

as

will

hel

injection

water

into a five

the

engine,

exchanger on

and

also

to

draw

is

empty,

freeze

to

be

drawn

is

empty,

the

raw

lay-up,

as

(some

it

in a bucket),

needed,

the

pump)

and

gasket.

the

flame

The

fogging

cylinders

run

in
p

intake

clean

the

stop

well

and

and

""'"

WESTERBEKE

Engines & Generators

50

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication

able,
sure

remove

trieal

Cylinder

If
WES1ERBEKE
fuel injectors

lublicating
from
two

Make

sealing washer for

NOTE:

months or
complete
tion
sticking during extended

Intake

Place a clean cloth,
opening of
shove
recommissioning,

you
note

exhaust port

Intake

Clean
cloth lightly
block
through-hull exhaust

to

Transmission

Check or change
engine
sion

its

and

flange

TRANSMISSION

infonnation.

Motor

and

cleaning of

if

access

to

the

starter permits

the

battery connections

the

starter.

Take

connections

removed

Lubrication

you

anticipate a

sticking

revolutions

sure

If

engine

beyond,

turns

pump

components

Manifold

the

cloth

may

need

to

remove

Manifold

tlle

filter

any

opening.

start-ul'!

long

recommends

for

access

oil

into

the

cylinders

to

the

cylinder

then

replace

you

have a replacement

the

injector

storage

it

is

every

additional 4 months

to

and

lightly

the

intake

manifold

out

of

sight.

and

an

the

assistance

the

cloth

can

be

blocked

[Gasoline

screen

in

soaked

in

lube

Also

port,

[Propulsion

fluid

in

is

to

be

layed

up

to

tlle

very

top

to

prevent corrosion.

normal at recommissioning.

touch

up

unpainted

with

an

anticorrosion

SECTION

the

starter ddve pinion

are·

shut

care

in

properly

from

the

its

easy

off

before

starter.

replacing

removal.

attempting

any

is

advis-

Make

[Diesel]

lay-up

period

(12

months

removing

to

the

cylinders. Squirt light

to

walls.

the

glow

and

is

going

to

wise

to

rotate

move.

This

storage

Thru-Hull

soaked

to

(If

it

attempt is

of a servicing dealer.) Make a

prior to start-up. The through-hull

in

the

tlle

prevent

Rotate

plugs

if

removing

fuel

line

be a lengthy

the

engine

will

help

periods.

Exhaust[Diesel]

in

lubricating

block

the

is

not

visible at

made

same

manner.

or more)

glow

plugs

the

piston rings

the

engine

or

injectors.

the

injector

return.

one,

by

to

allow

the

prevent their

oil,

opening. Do

to

start

the

by

12

hand

in

engine,

J

the

flame

arrester,

oil

around

place

an

oil-soaked cloth

Make a

note

Engine

the

transmission

12

months or

Wipe

areas.

Protect coupling and output

coating,

in

this

manual

the

to

J

more,

Lower

off

Refer

and

place a clean

flame
remove

as

required.

fill

grime

to

the

for

additional

arrester

in

the

cloths prior

the

transmis-

the fluid

and

to

elec-

or

hand

two

injec-

the

not

to

If

the

to

grease

SPARE

Lay-up
WES1ERBEKE engine

belts
spm..,s
used

to

or
during

the

PARTS

time

provides a

coolant

kit

and

the

SPARE

hoses

order

lay-up,

PARTS

good

need

items

such

section

to

see

replacement.

not

as

RECOMMISSIONING

The

recommissioning of

lay-up

seasonal

those

described

section

regarding
However,
counteracted before starting

1.

Remove

manifold,

2,

Remove
the

old

removed
Install

3.

Reinstall

up,

and
telminals
Check

4.

Remove
to

propel'

5,

Check

circuit

that
solution
engine
a

shOlt

up

the

lated

6.

Check

during

[Propulsion

7.

Make
in

the

generator

8.

Start

described

section

generally
in

some

of

any

rags that

or

flame

the

raw

gasket.

during

the

raw

the

batteries

reconnect

are

to

make

the

spark

tightness.

the

condition of

and

clean or replace

it

is

not

necessary

from

is

put

peliod of

heat exchanger ends

debris.

the

transmission

the

lay-up,

Engine]

certain
correct

at

the

engine

in

of

this

your

follows

the

PREPARATIONS

preparation

the

lay-up

the

were

arrester.

water

pump

Install

the

lay-up

(or a replacement,

water

pump

that

the

battery

clean

and

that

sure

that

plugs,

[Gasoline]

the

to

the

raw

water

into

operation,

time

with

fluid,

lower

all

electrical

position

stm·t

the

and

up.

[Generator]

in

accordance

PREPARATIONS

manual.

opportunity

if external

on

hand,

filters

of

this

WES1ERBEKE engine after a

for

starting

procedures

engine.

placed

cover

raw

cover

were

the

the

batteries

wipe

zinc

the

flush

coolant

the system

no

and

the

level

connections

there

to

inspect your

items

such

Check

your basic

or

replace tllose

and

zinc

anodes. Refer

manual.

the

same

procedures

FOR

STARTING

and

normal starts.

will

need

in

the

exhaust, intake

and

gasket

water

pump

impeller

if required).

with a new

removed

cables,

connections are

clean,

anode

anode

the antifreeze/fresh

adverse

clear

if

it

had

of

are

with

FOR

during

making

are

fully

re-gap,

in

the

as

needed. Note

system.

will

affects.

out

any

been

topped off

the

fluid

and

switches

no-loads

the

procedures

STARTING

cover

sure

and

raw

When
self-flush

as

drive

items

as

to

be

and

discm'd

gasket.

the

the

tight.

charged.

install

water

water

the

Also

accumu-

to

normal.

on

the

lay-

open

are

in

Batteries

If batteries are

make

sure

to

prevent

the

batteries

be

subjected

the

batteries

environment.

they
them

will

to

and

to

be

are

fTom

not

severe

store

fully

left

on

board duling

charged,

freezing.

remain

environmental
them

fully

in

If

a

and

will

there

exists

charged,

conditions,

warmer,

the

lay-up peliod,

remain that

any

doubt that

or

that they

remove

more

compatible

way,

will

--

---'-

.------'

Engines & Gen!,rators

51

.

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

VOLUME

Cubic

Inches

(in')

x

16.387

Imperial
Imperial
Imperial
Imperial
Imperial
Fluid
US
US
US

Pints
Quarts
Gallons
Quarts
Gallons

Ounces

Pints

(US
Quarts
Gallons

x

pt)

(US

(US

(IMP

(IMP

(IMP

(IMP

(IMP

29.573

x

.473

qt)

x

gal)

pt)

qt)
qt)

.946

x

x

gal)

gal)

=

3.785

MASS-WEIGHT

Ounces

Pounds

(oz)
(Ib)

x

28.35

x

.454

=

Grams

=

Kilograms

METRIC

(mm)

x

.0394

(m)

x

3.281

=

Feet

(km)

x

.0621

=

Cubic

Centim~ters

.568

=

Liters

(L)

x

1.137

=

Liters

x

4.546

=

Liters

x

1.201

=

US

Quarts

x

1.201

=

US

Milliliters

=

Liters(L)

=

Liters

=

Liters

(g)

(kg)

x

(L)

x

.034

x

2.113

x

(L)

.035

x

1.057

2.205

CONVERSION

=

Inches

=

Miles

x

.061

=in'

x

1.76

=

IMP

pt

(L)

x.88

=

IMP

qt

(L)

x

.22

=

IMP

(US

qt)

x

.833

Gallons

x

=

=

Ounces

=

Pints

=

.264

=

Ounces

=

Pounds

(US

gal)

Quarts

Gallons

x

gal

=

.833

DATA

IMP

qt

=

IMP

gal

PRESSURE

Pounds

Inches
Inches
Inches
Inches

Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

TORQUE

Pounds-Force
Pounds-Force

VELOCITY

Miles

Per

Hour

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Per

Hour
Kilometers
Miles

Per

Gallons
Kilometers

Sq

Inches
Feet

(Hp)

Per
Per

In

(psi)

(Hg)

(Hg)
(H20)
(H20)

(H20)

(ft-Ib)

(MPH)

x

.745

IMP

(MPG)

Liter

(Km/L)

US

Liter

(Km/L)

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

(in-Ib)

x

x

1.609

=

Kilowatts

(MPG)

=

Kilopascals

=

psi

=

Kilopascals

=

Inches

=

psi

=

Kilopascals

x

.113

1.356

=

=

Kilometers

x

.354

x

2.352

x

.425

x

2.352

x

2.036

of

Mercury

x

27.684

=

Newton

Newton

(Kw)

x

=

Kilometers
=

IMP

MPG

=

Kilometers

=

US

MPG

(kPa)

=

Hg

(kPa)

=

H20

(kPa)

x

Meters

Meters

Per

Hour

1.34

=

Per

x

x

x

4.026

(Nm)

MPH

Liter

Per

.145

.2961

13.783

(Nm)

x

(KPH)

(Km/L)

Liter

=

psi

=

Hg

=

=

H20

x

8.85

.738

x

.621

(Km/L)

H20

=in-Ib

=

ft-Ib

=

MPH

TEMPERATURE

Degree.fahrenheit
Degree

Celsius

(oJ;)

=

(OC

(OC) = (OF

X

1.8) + 32

-

32) x .56

Engines & Generators

52

-

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions

an inch

of

Decimal (in.)

1/64
1/32
3/64 0.046875
1/16
5/64
3/32 0.09375
7/64 0.109375

1/8
9/64
5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32 0.28125

19/64

5/16 0.3125

21/64

11/32

23/64

3/8 0.375

25/64

13/32

27/64

7/16 0.4375

29/64

15/32

31/64

1/2

Fractions of

an inch

17132
35/64

9/16

19/32

0.015625

0.03125

0.0625

0.078125

Metric (mm)

0.39688 33/64

0.79375

1.19062

1.58750

1.98437 37/64

2.38125

2.77812 39/64

0.125

0.140625

0.15625

0.171875

0.1875

0.203125

0.21875

0.234375

0.250

0.265625

0.296875

3.175

3.57187

3.96875 21/32

4.36562

4.76250

5.15937 45/64

5.55625

5.95312

6.35000

6.74687

7.14375

7.54062

5/8 0.625

41/64

43/64

11/16 0.6875

23/32
47/64

3/4 0.750

49/64 0.765625
25/32

51164

7.93750 13/16

0.328125

0.34375

0.359375

0.390625

8.33437

8.73125

9.12812

9.52500

53/64

27/32

55/64

7/8

9.92187 57/64

0.40625 10.31875 29/32

0.421875

0.453125

0.46875

0.484375

0.500

10.71562

11.11250

11.50937

11.90625

12.30312

12.70000

59/64
15/16

61/64
31/32
63/64

Decimal (in.)

0.515625

0.53125

0.546875

0.5625

0.578125

0.59375

0.609375

Metric

(mm)

13.09687

13.49375

13.89062

14.28750

14.68437

15.08125

15.47812

15.87500

0.640625

0.65625

0.671875

16.27187

16.66875

17.06562

17.46250

0.703125

0.71875

0.734375

17.85937

18.25625

18.65312

19.05000

19.44687

0.78125

0.796875

0.8125

0.828125

0.84375

0.859375

0.875

0.890625

0.90625

0.921875

0.9375

0.953125

0.96875

0.984375

1

1.00

19.84375

20.24062

20.63750

21.03437

21.43125

21.82812

22.22500

22.62187

23.01875

23.41562

23.81250

24.20937

24.60625

25.00312

25.40000

SUGGESTED

SPARE

PARTS

Carry

CONTACT

FUEUWATER.

\'l'IIr.\~t.Jll!i.,.~FILTERS

YOUR

HEAT

EXCHANGER

GASKET

Only

WESTERBEKE

AND

O-RING

Genuine

DEALER

END

Westerbeke

. - ..

FOR

ADDITIONAL

ZINC·ANODE

~.

FUEL

SYSTEM

HARDWARE;KI~T~2~~

Spare

SUGGESTIONS

FUEL

INJECTOR

Parts

AND

INFORMATION

MATCHING
DRIVE

BELTS

THERMOSTAT

GASKET

WESTERBEKE

each
Kit
Kit

packaged

"A"

uB"

in

includes

is

for

more

KIT

A

ZINC

ANODES

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER
IMPELLER
FUEL

SYSTEM
FUEL

PUMP

AND

also

offers

two

Spare Parts

a rugged hinged toolbox.

the

basic spares.

extensive

KIT

INLET

off."shore

GASKET

HARDWARE

FILTER

KIT

cruising.

SPARE

Kits,

PARTS

KITS

MOLDED
HOSE

KIT

INA

CANVAS

CARRYING

BAG

..

KIT

B

ZINC

ANODES

DRIVE

BELTS

OIL

FILTER

FUEL

FILTER

HEAT

EXCHANGER

IMPELLER

INJECTOR
OVERHAUL
GtOW;PEUG
FlIELSYSTEM

FUEfPUMPIN~E:rJIL"ER

KIT

GASKET

GASKET

KIT

~AROWARE

KIT

-

---'-------.=_.-_.

Engines & Generators

54

~WESTERBEKE

Engines & Generators

'.

,

'I

1161/811