Westerbeke 7A-1, 11A-1 Operator's Manual

f4t.

o q

IiLD~'

OPERATORS

. -

7A·1

MARINE

PUBLICATION

and

DIESEL

1 st Edition!

April

MANUAL

11A·1

ENGINES

NO.

45145

2001

~"'~

WESTERBEKE

J

150

TEL:

~~~~

NMMA

HANCOCK

Member

CORPORATION·

National

JOHN

(508)823-7677.

ROAD,

FAX:

(508)884-9688.

Marine

MYLES

TAUNTON,

STANDISH

MA

WEBSITE:

Manufacturers Association ,

INDUSTRIAL

02780-7319

www.WESTERBEKECOM

U.S.A.

PARK

OPERATORS

MANUAL

7A·1

MARINE

~r~

~

~~~~

NHHA

~,.,~

DIESEL

PUBLICATION

15t Edition!

'WESTERBEKE

W£ST£RB£K£ CORPORATION· MYL£S STANDISH INDUSTRIAL PARK

150

JOHN HANCOCK

TEL: (508)823-7677·

Member National Marine Manufacturers Association

and

NO.

April

ROAD,

TAUNTON,

FAX:

(508)884-9688· WEBSITE

11A·1

ENGINES

45145

2001

MA

02780-7319 U.S.A.

www.WESTERBEKECOM

CALIFORNIA

PROPOSITION

Diesel engine exhaust and some

of

its

constituents are known

the State

of

California

cancer, birth defects, and other

reproductive harm.

A

65

WARNING

to

cause

WARNING

to

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

IF

GET seek until

gasses

gas.

can

Wea/cness

YOU

OUT

OR

ANYONE

INTO

medical

it

has

been

and

contain

Carbon

include:

Sleepiness

THE

attention.

Carbon

Monoxide

and

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

Monoxide,

is

poisonous

Symptoms

-

Muscular

•

-Inability

IMMEDIATELY. down

and

repaired.

This

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON Iiving/sleeping

They

are

obtainable

of

Throbbing

Vomiting

to

ANY

the

unit

and

near

your

a/so

MONOXIDE inexpensive

at

your

an

odorless

and

can

Carbon

Twitching

OF

DECAL

quarters

Monoxide

in

Temples

Think

Coherently

THESE

«symptoms

and

do

is

should

engine

recommends

DETECTORS

of

and

local

marine

and

cause

SYMPTOMS,

persist,

not

restart

provided

be

your

easily

fixed

or

generator.

installing

in

vessel. store.

by to

a

the

SAFETY

INSTRUCTIONS

INTRODUCTION

Read these safety instructions caused

by

failure

tions.

Know necessary and your The

precautions

machinery.

foUowing

the American

PREVENT

A

WARNING:

while

engine

power.

Lethal

• Do not operate this machinery without electrical enclosures and covers in place.

• Shut

• Use insulated mats whenever working on electrical

• Make sure your clothing and skin are

• Remove wristwatch and all jewelry when working on

•

• Electrical shock results from handling a charged

off

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment. Do

not connect utility shore power to vessel's circuits, except through a ship-ta-shore double throw transfer switch. Damage to vessel's result

if

capacitor. Discharge capacitor by shorting terminals together with

PREVENT

A

WARNING:

exhaust

very

hot!

A

WARNING:

to

follow fundamental

when

dangerous

to

safety

instructions

Boat

and

ELECTRIC

lID

nDt

is

running,

voltage

electrical power before accessing electrical

this procedure

an

insulated tool.

BURNS -HOT

lID

system

components. A running

Steam

carefuUy.

Most

rules

accidents

and precau-

conditions exist and take the

protect yourself, your personnel,

are

in

compliance

Yacht

Council

(ABYC)

standards.

SHOCK

touch

AC

Of

wlren

is

present

is

not followed.

electrical connected

at

these

CfJIInectiDIIS

to

connections!

dry,

not damp

AC

generator may

shore

AC

ENGINE

not

touch

hot

engine

parts

Of

engine

gets

can

cause

injury

Of

death!

with

are

PREVENT

A

• Prevent flash sparks to occur near the other potential sources a suitable container to catch fuel

• Keep the compartment and the engine clean and debris to minimize the chances fuel

• Be aware - diesel

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine.

•

All when

tilated area away from spark-producing equipment and

out

• Do not fill the

• Shut off the the spill. DO NOT allow any smoking, open sources ing. fuel

•

• Be sure all

• Be certain

• Make sure a

BURNS -FIRE

WARNING:

line or

and engine

fuel

Fire

can

cause

injury

or

fires.

Do not smoke or permit flames or

fuel

line,

filter,

fuel

of

spilled

fuel

or

fuel

all

fuel

when removing the

filters.

of

fire.

Wipe

oil.

fuel

will burn.

death!

pump, or

vapors.

up

free

all

spilled

BURNS -EXPLOSION

WARNING:

Of

death!

fuel

handling and storing fuels. Store

of

the reach

fuel

Ensure proper ventilation exists when servicing the

system.

Do

not alter or

free

of

leaks.

properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the for

all

applications encountered in this environment.

vapors

fuel

system.

of

fire

fuel

fire

Explosions

are

highly

of

children.

fuel

service valve

Take

near

the

modifY

supplies have a positive shutoff valve.

line fittings are adequately tightened

extinguisher

from

fuel

rapors

Open

and ventilate cabin

explosive.

tank(s) while the engine

care in catching

fuel

system

the

fuel

Use

extreme

fuel

at

the engine

any

flames,

or

engine

system.

is

installed nearby and

NFPA

are

can

cause

care

in a well-ven-

is

running.

when

fuel

that might

when

appropriate

servicing

or other servic-

Use

and

of

is

•

In

case

of

an

engine overheat, allow the engine to cool

before touching the engine or checking the coolant.

Engines & Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing Remove the negative lead first and reconnect

•

Make starting.

•

Make re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

•

Do

not smoke or allow being serviced. Lead acid batteries highly explosive arcing or by lit tobacco products. Shut off equipment in the vicinity during servicing.

• Never connect the negative positive

Do

not test the battery condition by shorting the terminals together. Ventilate accumulation disturb is

being charged.

•

Avoid

burns wristwatch, rings, the

battery.

• Always turn the battery charger offbefore disconnecting the

battery connections. Remove

and reconnect

BATTERY

A

WARNING:

severe

•

When level, protection. Batteries contain sulfuric destructive. off at once with into electrolyte caps.

STARTING

Accidental

certain all personnel

certain

all

covers, guards, and

starling

are

clear

can

of

EXPLOSION

Battery

(+) connection terminal

Sparks could ignite battery

any compartment containing batteries

of

the

battery charger connections

contacting

or

sparks that could cause

it

explosion

an

gas,

which

to

explosive gases.

the

terminals with tools, etc.,

and any

last when servicing

can

open

flame

emit

can

be

prevent

(-)

battery cable

of

To

an

other jewelry before handling

the

ignited

electrical

the starter solenoid.

explosion.

ACID

Sulfuric

injury

or

death!

servicing the battery

wear rubber gloves, a rubber

If

it

the

eyes inadvertently when

comes water.

acid

in

batteries

or

checking the electrolyte

apron,

in

contact with your

Acid

may

splash

removing

cause

injury

the

it

last.

the

engine before

hatches

are

cause

injury

near the battery

hydrogen,

by

electrical

all

electrical arcing

to

the

gases

or

fuel

to

avoid

sparks,

while

the battery

to

Remove

negative

the

acid

battery.

can

and

which

skin,

on

the

lead

cause

eye

skin

engine.

a

vapors.

prevent

do

prevent

first

is

wash

or

not

TOXIC

• Ensure that the exhaust

• Be sure the unit

• Don't run the generator set or engine unless

• For additional information refer

•

it

EXHAUST

A

WARNING:

discharged regularly water-injected exhaust elbow

Run

blowers

equipped with a functioning detector that complies boat builder or dealer

(educational information

A

WARNING:

odorless

nausea

Do

not use copper tubing in

fumes

can systems. copper tubing resulting

• Do not install exhaust outlet where exhaust through portholes, vents, or exhaust discharge outlet

enter

the

flow

of

exhaust.

• Although diesel engine exhaust gases

exhaust gas

is

present symptoms or signs poisoning

Dizziness Throbbing Headache Muscular twitching

Nausea Vomiting Inability

AVOID

•

MOVING

A

WARNING:

or

death!

Do

not service the engine situation arises in which make

operating adjustments, touching moving parts and components.

GASES

Carbon

from

for

leaks

when

gas.

or

death!

rapidly

Exhaust sulfur causes rapid deterioration

exhaust

fumes

in

are:

monoxide

system

the

engine.

and

make

and

its

surroundings

running

with

for

on

Carbon

Inhalation

destroy

in

is

discharge

Avoid

overloading the craft.

from

gasoline engines, carbon monoxide

diesel

exhaust

of

carbon monoxide inhalation

Weakness

(CO)

is a

is

adequate to

Check the exhaust

sure

the

exhaust

is

securely

the

generator set or

marine

ABYC

installation of approved

to

Carbon Monoxide).

monoxide

produces

diesel

copper

exhaust/water

air

conditioners.

near the waterline, water

outlet

fumes.

in

temples

and

sleepiness

to

think coherently

are

carbon

A-24.

ABYC

(CO)

flu-like

exhaust

tubing

and

close

attached.

well

Consult your

in

leakage.

are

not

Some

PARTS

Rotating

parts

can

cause

while

it

is

running.

it

is

absolutely necessary use

extreme

hot

exhaust system

deadly

gas!

expel

gases

system

manifold!

ventilated.

engine.

the

boat

monoxide

detectors.

T-22

is

an

invisible

symptoms,

systems.

exhaust

can

or

Diesel

of

be

drawn

If

the engine

restrict

as

toxic

of

the

or

injury

If

a

to

care

to

avoid

is

could

the

as

Engines & Generators

ii

SAFETY

•

Do

not wear loose clothing or jewelty equipment; tie back jackets, shirts, sleeves, rings, necklaces or bracelets that

be

could

•

Make Keep places

•

Do

HAZARDOUS

A

hearing

• Never operate

•

Do

enclosures

A

mentally

ENGINE

Preparations to install ough examination (ABYC) standards. These standards are a combination sources including

Sections

All installations must Regulations

caught

sure

all

protective shields

at

all

times.

not check

NOISE

WARNING:

loss!

not run engines

open.

WARNING:

IIr

physically

INSTALLATIONS

of

the

ABYC

P-l Exhaust systems P-4

Inboard engines

E-9

DC

Electrical systems

(FCR).

long

hair and avoid wearing loose

in

moving parts.

attaching hardware

and

guards in their respective

fluid

levels while the engine

High

noise

levels

an

engine without its mufiler installed.

for

long periods with their

011

not

WllrIc

lin

incapaCitated

an

engine should begin with a thor-

of

the American Boat and

the

USCG

and the

standards

comply

of

with the Federal

when

servicing

is

properly tightened.

is

operating.

can

cause

machinery

NFPA.

particular interest

by

fatigue!

when

Yacht

Code

Council's

INSTRUCTIONS

Yllu

of

are:

of

ABYC, INSTAlliNG

Read

for

tions

ABYC (American Boat

Safety Standards

Order

NFPA

Fire Protection Standardfor Motor Craft

Order

are

USCG

USCG 33CFR183

Order

NFPA

the

following

safety codes and standards. Follow their recommenda-

when

from:

ABYC 3069 Solomons Island Edgewater,

(National Fire Protection Association)

from:

NFPA

11

Tracy

Avon

Industrial Park

Avon,

MA

(United States Coast

from:

U.S.

Government Printing

Washington,

AND

USCG

DIESEL

installing your

MD

Drive

02322

ABYC,

for

Small Craft

21037

D.C.

20404

ENGINES

PUBLICATIONS

NFPA

and

USCG

engine.

and

Yacht

Council)

Rd.

Guard)

Office

FOR

pUblications

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines and generators,

attention

CODES

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

be

paid to the following information:

AND

REGULATIONS

it

is important that strict

SIPHON-BREAK

For installations where the exhaust manifold/water-injected exhaust elbow is close to will be below the vessel's waterline, provisions in the raw water supply hose to the exhaust elbow. This hose mum

of

20 in.

(51

cm) above the vessel's waterline. Failure to use a siphon-break

when

the

exhaust manifold injection port is at or below

in raw water damage to the engine

If

you have any doubt about the position the vessel's waterline under any the vessel is not underway, tect your engine.

NOTE:

A siphon-break requires periodic inspection ation. Failure to properly maintain a siphon-break can result in catastrophic engine damage. Consult the siphon-break manufacturer

EXHAUST

The exhaust hose must prevent water from entering the exhaust under any sea conditions and at any angle

the vessel's hull.

SYSTEM

install a siphon-break. This precaution is necessary to pro-

be

certified for marine use. The system must be designed to

and

of

the vessel's various operating conditions

must

be

made to install a siphon-break

must

be looped a mini-

the

load waterline will result

possible flooding

of

the water-injected exhaust elbow relative to

for

of

the

boat.

or

when

and

cleaning to ensure proper oper-

a proper maintenance schedule.

or

of

A

detailed

engines

40-page

and

generators,

Marine

is

Installation

available

Engines & Generators

Manual

from

your

iv

covering WESTERBEKE

gasoline

dealer.

and

diesel,

TABLE

OF

CONTENTS

Introduction

7A-1 7A-1

11A-1

Preparations

Starting/Stopping

Engine

Daily

Maintenance Exhaust

Lubrication

Cooling

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

Warranty Procedures ............................................................ 2 Raw Water Pump ................................................................. 22

Product Software ................................................................. 2 Inspecting/Changing the Raw Water Pump Impeller

Notes, Caution and Warnings .............................................. 2 Raw Water Intake ................................................................. 22

Model No.lSerial No. Location ........................................... 2 Raw Water Intake Strainer ................................................... 22

Component Locations .......................................................... 3 Siphon-Break ....................................................................... 23

Understanding the Diesel Engine ........................................ 3 Draining the Cooling

Ordering Parts ...................................................................... 3

Spares and Accessories ........................................................ 3 Description ........................................................................... 24

Protecting Your Investment ................................................. 3 Air Filter ....................................................................... 24

Diesel

Engine

Specifications

Diesel

Engine

Parts

Identification

Diesel

Engine

Specifications

Diesel

Engine

Parts

for

Initial

Start-Up

Diesel FueL .......................................................................... 8

Care

of

the Fuel Supply ............................................... 8

Fuel Additives ............................................................. 8 Fuel Lift Pump .....................................................................

Engine

OiL

.......................................................................... 8 Fuel Filter ............................................................................. 25

Transmission Fluid .............................................................. 8 Replacing the Fuel Filter .............................................. 25

Pre-Start Inspection ............................................................. 8

Procedure

Electric Starting ................................................................... 9

Electric Starting Procedure .......................................... 9

Low Battery Electric Starting Procedure ..................... 9

Manual Starting (Hand Cranking) ....................................... 9

Automatic Decompression Device ............................

Cold Starting Device ..................................................

Manual Starting Procedure ........................................

Starting Under Cold Conditions ................................

Operating the Engine .........................................................

Start-Up Check List... .....................................

Initial

Stopping the Engine ...........................................................

Break-In

Engine Break-In Procedure ................................................

Break-In Check List. ..........................................................

Transmission Break-In .......................................................

Operation

Description .........................................................................

Exhaust

Description .........................................................................

Engine Checking the Changing the

Testing the

Raw Water Cooling

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

Coolant Temperature Switch .............................................

Procedure

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

Daily Operation Check-List. ......................................

Transmission ..............................................................

Schedule

System

Siphon-Break .............................................................

System Precautions ..............................................

Carbon Monoxide ......................................................

Carbon Monoxide Warning Decal .............................

Carbon Monoxide Detectors ......................................

Insulation ...................................................................

Overcranking ..............................................................

System

Oil Pressure ReliefValve ...........................................

Low

OiL

Removing the Changing the

Adding the New

System

CheckinglReplacing the Thermostat... ......................

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

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

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

Oil Pressure Alarm Switch ................................

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

Oil ................................................................

OiL

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

Old Oil ...............................................

Oil Filter (Model

Oil Pressure ..................................................... 20

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

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

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

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

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

Identlfication

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

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

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

llA-l

only) ............

Oil... ............................................... 20

2

Cooling

Air

Intake

System

(continued)

System ............................................... 23

Filter

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

4 Maintenance ................................................................. 24

5

Water

Heater

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

6 Water Heater Installations .................................................... 24

.7

Fuel

System

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

8 Diesel FueL .......................................................................... 25

Fuel Additives ...................................................................... 25

Care

of

the Fuel Supply ........................................................

Fuel Lines ............................................................................. 26

9

IO 10 12 11 12 12

.12

12

13

13 13 13 13

13

13 14 16 16 16 16 16 16 17

.17

17 18 18 18 18 18 18 19

.19

19

21 21 21 21 21

Fuel FilterlWater Separator .................................................. 26

Fuel Injection Pump ............................................................. 26

Fuel Injector ......................................................................... 26

Bleeding the Fuel

Spare Parts ............................................................................ 26

DC

Electrical

Control Panel. ....................................................................... 27

Engine Circuit Breaker ......................................................... 27

Battery .................................................................................. 27

Alternator Troubleshooting .................................................. 28

7A-I Marine Diesel Engine Wiring Diagram #45593 ......... 30

7 A-I Marine Diesel Engine Wiring Schematic #45593 ......

11A-1 Marine Diesel Engine Wiring Diagram #44542 ....... 32

11A-l Marine Diesel Engine Wiring Schematic #44542 .... 33

Glow Engine

Tightening the Cylinder Head .............................................. 35

Valve Clearance Adjustment. ............................................... 35

Engine Compression Test. .................................................... 35

Testing the Fuel Injector ...................................................... .36

Drive Belt Adjustment. ........................................................ 38

Engine Hurth Hurth Lay-Up 7A-1 & 11A-1 Standard Metric Standard Suggested

System

Volt

DC

Battery Care ................................................................. 27

Checking the Service Battery ....................................... 27

Testing the Alternator ................................................... 28

Checking the Service Battery ....................................... 29

Plugs

(ModeI7A-1 only) ................................................... 34

Adjustments

Removing the Fuel Injector .......................................... 36

Fuel Injector Components ............................................ 36

Checking the Injection Starting Pressure ..................... 36

Tightness

Inspecting the Spray Pattern ........................................ 37

Checking the Nozzle Body and Needle Valve ............. 37

Reassembly ................................................................... 37

Injector Installation ...................................................... 37

Checking Belt Tension ................................................. 38

Adjusting Belt Tension ................................................. 38

Troubleshooting

HBW

Transmission

HBW

Transmission

and

Recommissioning

Torque

Hardware/Sealants & Lubricants

Conversions

and

Metric

Spare

System .................................................... 26

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

Control Circuit... ............................................... 27

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

of

the Valve Seat. ......................................... 37

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

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

Troubleshooting

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

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

Specifications

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

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

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

Conversion

Parts

Kits

Oata

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

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

...

22

24

25

25 25

27

31

35

39 42 45 46 48 49 50 51 52

Engines & Generators

1

This

WESlERBEKE WESlERBEKE'S technology. dependable you

This

Diesel both models, Catalog available to

install

WESlERBEKE'S

In

order

it

is manual carefully Should WESlERBEKE

WARRANTY

Your package. registering registration information, commission

Customer

We

take

performance

for

selecting

is

the

Engines.

models;

the

is

to

important

is

your

Operators

where

applicable

also

provided

from

your

this

equipment,

get

the

that

designed

and

observe

engine

Most

WESlERBEKE.

PROCEDURES

WESlERBEKE

If

you

have

your

warranty

form,

including

date.

Identification

Diesel

Engine

many

years

great

pride

of

our

Manual

for

of

the

information

model

name

for

your

WESlERBEKE

contact

Installation

full

use

and

you

operate

to

help

you

all

the

safety

require

servicing,

dealer

for

assistance.

Warranty

not

received a customer

60

days

please

contact

the

unit's

is a product

of

experience

in

the

superior

engines

the 7 A-I

applies

will

engine,

dealer.

your

WESlERBEKE

Manual.

benefit

from

and

maintain

do

this.

precautions

contact

is

included

after

the

factory

serial

Card

of

and

advanced

durability

and

generators.

and

IIA-I

in

this

manual

to

only

one

be

indicated. A Parts

and a Service

If

you

your

engine,

it

correctly.

Please

read

throughout.

your

nearest

in

the

documentation

identification

submitting

number

in

writing

and

the

INTRODUCTION

Thank

Marine

applies

of

the

Manual

are

planning

dealer

this

manual

warranty with

and

two

This

to

is

for

card model

PRODUCT

Product software (tech data, and

catalogs) provided

WESTERBEKE are

WESTERBEKE CONTENT OF SUCH WARRANTIES

THERETO, COMPLETENESS BE

UABLE INCURRED OF

THE

WESlERBEKE between unavoidable software. products,

not

and

authority but

is

WESlERBEKE

determine being

NOTES,

As

this

maintenance engine, CAUTIONS,

NOTE:

SOFTWARE

INCLUDING

FOR

IN CONNECTION

FURNISHING

printings

existence

The

product

whether

cannot

be

on

the

imperative

the

accuracy

consulted

CAUTIONS

manual

takes

schedules,

critical

information

and

An

operating

parts

lists, manuals,

from

sources other

not

within

WESTERBEKE's

CANNOT BE RESPONSIBLE

SOFTWARE,

OR

REPRESENTATIONS

ACCURACY,

THEREOF

ANY

customers

of

WESlERBEKE

of

software

from

WESlERBEKE

relied

upon

respective

that

appropriate

or

the

supplier

and

by

the

customer.

you

and

WARNINGS.

procedure

AND WIll. IN

TYPE

OF

WITH

OR

USE

should

keep

earlier

WESlERBEKE

provided

exclusively

product.

AND

through

It

representatives

in

question

currentness

WARNINGS

the

troubleshooting

will

be

highlighted

An

essential

DAMAGE

OF

explanation

than

MAKES

WITH

TIMEUNESS

OR

SUCH

in

mind

product

with

WESlERBEKE

or

other

as

the

not

only

be

of

the

operating

of

to

note.

brochures

control.

FOR

THE

NO

RESPECT

OR

NO

EVENT

OR

INJURY

ARISING OUT

SOFTWARE.

the

time

span

software

makes

consulted

product

your

by

and

product suppliers,

definitive

good

of

to

software

procedures,

marine

NOlES,

follows:

the

must

sense

I~'WESIERBEKE

I

Engines & Generators

Customer

WESTERBEKE MAIN

HOMETOWN,

Mode17A-1

Expires Ser.

#74860/197-E003

Your

WESlERBEKE

alphanumeric

date

code

character decade

(D=

represents numbers

Identification

STREET

3116102

number

is

at

the

end

followed

after

1990s,

the

year the

by

E=2000s),

in

character

OWNER

USA

7 A-I/IIA-I

that

indicates

of

the

serial

three

numbers.

the

decade,

represent

Engine

the

number,

The

fITSt

number

and

the

serial

date

of

and

character

second

month

number

manufacture.

consists

of a

indicates

after

the

character

and

third

of

manufacture.

is

an

The

the

A

CAUTION:

observed. your

engine.

A

WARNING:

followed.

MODEL

The identification exhaust on

vide a quick

ordering

NO./SERIAL

engine's

manifold/elbow.

the

illustration

repair

can

result

can

result

model

plate

mounted

of

reference

parts.

Procedures

in

the

damage

Procedures

in

pelSDnai

NO.

LOCATION

number

and

serial

on

the

Take

the

nameplate

when

seeking

ENGINE

mEITIFICATION

which.

injury

number

engine

time

to

shown

technical

PlATE

if

not

strictly

Dr

destruction

if

not

properly

or

loss

are

located

block,

below

enter

this

information

below,

as

information

of

his

of

life.

on

the

will

an

pro-

and/or

Engines & Generators

2

INTRODUCTION

COMPONENT

Component of

the

engine located. straddling is

at

Left

your

UNDERSTANDING

The

diesel mechanism above a closed

type

as

on a gasoline

types

of

valves,

system.

Therefore,

ventive

maintenance

factors

are lubricating replaced contaminants essential.

same specifically

The in ignition injection

brand

diesel

its

method

at

systems

ORDERING

Whenever replacement parts are needed, always provide the engine model number and serial number. provide tify your engine. description and part number for each part needed (see the Parts List). Insist upon Westerbeke packaged parts because

the same specifications

LOCATIONS

locations

the

left,

engine

is

to

proper and

the

Another

of for

engine

pump -which

in

which

is

and

right

engine,

the

right

closely

essentially

crankcase.

engine,

camshaft,

a

great

extent, a diesel as a gasoline

ventilation

cooling

time

periods

(water,

sediment,

important

high

detergent

diesel

does

of

handling

are

replaced

this

manual

the

end

sides

facing

side

is

THE

resembles

the

The

piston,

systems.

specified.

engines.

differ

and

performs

at

are the

at

DIESEL

same.

crankshaft

and

factor

diesel

from

firing

by a single

PARTS

us

with this information so

In

addition, include a complete part

will

fit

or generic parts are frequently not made

as

original equipment.

are

referenced

which

the detennined front

of

the

your

right.

ENGINE

the

gasoline

The

cylinder

the

diesel

connecting

engine

engine. proper Fuel

filter and

etc.)

in

the

is

the

lubrication

the

gasoline

of

fuel.

the

function

we

from

raw

water

pump

as

follows:

engine:

is

of

engine

rod

requires

The

maintenance

elements

frequent

fuel

consistent

The

component -the

of

may properly iden-

the

engine,

is

arranged

the

same

has

the

and

lubricating

the

most

important

of

must

checking

system

is

use

oil

designed

engine,

carburetor

both.

You

imagine

same

of

however,

the

front

is

left

side

since

general

same

the

fuel,

be

for

also

the

and

fuel

must

pre-

the

to

SPARES

Certain spare parts will be needed to support and main-

tain your WESTERBEKE engine when cruising (see

SUGGESTED

simple item such

to you with a suggested spares and accessories brochure assist proper WESTERBEKE parts.

PROTECTING

Care

resulted thousands manufacturer in

viced

NOTE:

•

AND

ACCESSORIES

SPARE

as

a proper fuel filter can be difficult

obtain along the

you

in preparing

way.

YOUR

at

the

factory

during

in a WESTERBEKE

of

hours

of

dependable

cannot

control

the

vessel

or

the

manner

in

the

field.

This

Six

important

Proper

engine

An

efficient

anti-siphon Changing Proper

maintenance

maintenance Use

clean,

Wmterize

RECOMMISSIONING

steps

installation.

well-designed

break

to

the

engine

schedule

filtered

diesel

your

engine

PARTS

KITS). Often even a

WESTERBEKE can provide

an

on-board inventory of the

INVESTMENT

assembly

in

is

up

prevent

oil

of

all

in

according

and

thorough

engine

capable

service.

how

or

where

which

the

unit

to

the

buyer/owner-operator.

to

ensure

long

exhaust

system

water

from

every

100

operating

engine

components

this

manual.

fuel.

to

the

section

in

this

of

many However, the

engine

is

operated

engine

life:

that

entering

hours.

LAY-UP

manual.

testing

have

the

is

installed and

includes

the

engine.

according

AND

to

ser-

an

to

the

Engines & Generators

3

7

A-1

DIESEL

ENGINE

SPECIFICATIONS

Engine

Type

Aspiration Govemor Combustion Bore and Piston Crankshaft

Direction Compression Maximum

(at Manual

Engine Dimensions

NOTE: crank width

Dry Max. Max.

System

Stroke

Displacement

of

Rotation

Torque

2500

rpm)

Starting

Stop

An

inserted

handle

increases

by

4.5

in

Weight

Angle

of

Angle

of

ENGINE

Ratio

System

standard

the

(115

mm)

Installation

Operation

SPECIFICATIONS

Diesel,

four-cycle,

vertical, Naturally Mechanical, Direct

injected

3.23

in. x 2.17

17.7

cu.

Clockwise, (raw

water

20:1

11.0

ftIIbs

Hand-crank, decompression

Manual

type

Height: Width: Length:

151

Ibs

Not

to

exceed 1 0°

Not

to

exceed

in-line

overhead

aspirated

centrifugal

in.

(290

when pump

(1.5

kg-m)

with

17.1

in

14.9

in

22.5

in

(68.5

kg)

15°

one

cylinder,

type

(82.0

mm x 55.0

cm')

viewed

end)

automatic

device

(433.7 (379.2 (571.3

in

all

directions

valve

from

mm) mm) mm)

raw

water

mechanism

the

cooled,

mm)

front

Lubrication Sump

capacity

Operating

Oil

(engine

hot)

Oil

Grade

Lube

oil

Strainer

Cooling

System

Operating

Temperature

Raw

Water

Raw

Water

at

3600

rpm

Raw

Water

Emission

Control

Exhaust

ManifoldlElbow

Exhaust

Elbow

LUBRICATION

System

Pressu

re

COOLING

Pump

Row,

Connection

EXHAUST

Systems

Connection

SYSTEM

Forced

lubrication

1.3

qts.

(1.25

25.6-56.9

API

specification

SAE

30,

Full-flow,

liters)

psi

(1.8-4.0

10W-30,

intemal

by

gear-driven

CF

or

15W-40

SYSTEM

Raw

water-cooled

thermostatically 13D-150°F(55-66°C) Positive

displacement,

gear-driven,

7.3w-8.456

112

in.

(12.7

block,

controlled

sen-priming

gpm

(7~

mm)

1.0.

SYSTEM

Meets

U.S.C.G.

Regulation cast 1-112

aluminum,

in.

(38.1

raw

mm)

water

1.0.

kg/cm')

CG-4

neoprene

Ipm)

33

CFR

cooled

pump

impeller,

183

Compression

Valve

Seat

Angle

Valve

Clearance

(engine

cold)

Engine

Timing

Injector

Pressure

Engine

Speed

Fuel

System Fuel Fuel

Lift

Pump

Fuel

Injection

Fuel

Injector

Fuel

Injection

Injector

Pressure

Fuel

Consumption (full

load)

Fuel

Filter

Fuel

Supply and

Return

Lines

Air

Row

(engine

combustion)

TUNE-UP

Pressure

Pump

Timing

SPECIFICATIONS

478.5

psi

(33.6

435.0 Intake Intake

Exhaust

39.0

mm

2900

psi

Idle:

1000 -1200 Cruise: Maximum:

FUEL

Open

flow, No.2 Mechanical Bosch Direct 39

mm

2900

psi

0.46

U.S.

Primary, 1/4

in.

5116

in.

15.3

cfm

kg/cm')

psi

(30.6

kg/cm')

45°;

Exhaust

0.008

in.

(0.2

0.008

in.

(0.2

BTDC

static

(203.9

kg/cm')

2000 -2500

2900 -3000

SYSTEM

sen-priming,

diesel

oil,

cetane

1.6

ft.

(0.5

type

injection

BTDC

static

(203.9

kg/cm')

gal./hr.

(1.76Iiterlhr.)

replaceable

(6.35

mm)

(0.43

1.0.

mm)

cmm)

(7.94

45°

mm)

rpm

rating

m)

filter

minimum

1.0.

maximum

standard minimum

rpm

sen-bleeding

of

45

or

lift

max.

higher

Electrical

System

Battery

Charging

Altemator Starting

Motor

Cold

Cranking

General

Gear

Ratio

(optional)

Propeller

used

the

engine

to

at

full

gear,

Shaft of

open

reach

underway

Ruid

Rotation

rpm

forward Lubricating Transmission

capacity Propeller

Direction

ELECTRICAL

Amps

TRANSMISSION

must

allow

its

rated

throttle

in

Sump

12

volts

DC,

circuit

breaker

30

amp,

12

solid

state

12

volt

solenoid,

70

amps@71°F

HURTH

HBW

hardened multiple

disc

2.05:1 120 x 8 P

12

0 x 6 P

ATF-

type

0.37

qts

(0.35

Right

hand-standard

SYSTEM

negative

protected

volts,

belt-driven,

internal

regulator

actuated

(22°C)

40

Standard

helical

gears,

clutch

two

blade

three

blade

A

or

DEXTRON

liters)

ground,

with

shift

Transmission,

with

a

servo-operated

RH

-/I

or

11/

transmission

case-

Engines & Generators

4

AUTOMATIC

DECOMPRESSION DEVICE

HAN~-CRANK

HANDLE

GUIDE

RAW WATER PUMP

7

A-1

DIESEL

ENGINE

PARTS

IDENTIFICATION

flEXIBLE MOUNTS

TRANSMISSION

RAW

WATER

INTAKE

CONNECTION

FUEL

INJECTOR

CYLINDER HEAD

---t--Hl'f-H,-#'4:;;;t,i~M"-:;5~~~~

WATER

INJECTED

MANIFOLDJELBOW

FUEL PUMP

FUEL

EXHAUST

INJECTION

FILTER

TRANSMISSION OUTPUT

FLANGE

Engines

& Generators

5

11

A·1

DIESEL

ENGINE

SPECIFICATIONS

Engine

Type

Aspiration Governor Combustion Bore Piston Crankshaft

Direction Compression Maximum

at Manual

Engine Dimensions

NOTE: crank width

Dry Max. Max.

and

Stroke

Displacement

of

Rotation

Torque

(2400

rpm)

Starting

Stop

An

inserted

handle

by

4.5

Weight

Angle

of I nstallation

Angle

of

System

increases

in.

ENGINE

Ratio

System

standard

the

(115

mm)

Operation

SPECIFICATIONS

Diesel,

four-cycle,

vertical, Naturally Mechanical, Direct

injected

3.74

in. x 2.91

31.95

cu.

Clockwise, (raw

water

20:1

21.3

ftIIbs

Hand-crank, decompression

Manual

type

Height: Width: Length:

238

Ibs

Not

to

exceed 1 0°

Not

to

exceed

in-line

overhead

aspirated

centrifugal

in.

(524.0

when

pump

(2.9

kg-m)

with

device

21.0

in

21.3

in

23.8

in

(108

kg)

15°

one

cylinder,

valve

type

(95.0

mm x 74.0

cm')

viewed

from

end)

automatic

(532

mm)

(540

mm)

(603

mm)

in

all

directions

raw

water

mechanism

the

cooled,

mm)

front

Lubrication Sump

Capacity

Operating (engine

Oil

Cooling

Operating Raw

Raw at

Raw

Emission Exhaust Exhaust

Oil

hot)

Grade

Riter

System

Temperature

Water

3600

rpm

Water

Control ManifoldlElbow Elbow

LUBRICATION

System

Pressure

COOLING

Pump

Row,

Connection

EXHAUST

Systems

Connection

SYSTEM

Forced

lubrication

1.7

qts.

(1.6

liter)

25.&-56.9

API SAE

Full-flow,

psi

(1.8-4.0

specification

30,

10W-30,

paper

element,

SYSTEM

Raw

water-cooled

thermostatically

13D-150°F Positive

gear-driven,

7.399-8.456

112

in.

controlled

(55-66°C)

displacement,

seH-priming

gpm

(12.7

mm)

SYSTEM

Meets

U.S.C.G.

Regulation

Cast

aluminum,

1-112

in.

(38.1

raw

mm)

by

gear-driven

kg/cm')

CF

or

CG-4

15W-40

block,

neoprene

(7-8lpm)

1.0.

water

1.0.

spin-on

33

CFR

cooled

pump

type

impeller,

183

Compression

Valve Valve

(engine Engine Injector Engine

Fuel Fuel Fuel Fuel Fuel I njector Fuel Injector Fuel

(full Fuel Fuel

and Air

Row

(engine

Pressure

Seat

Angle

Clearance

cold)

liming

Pressure

Speed

System

Uft

Pump

Injection

Pump

Injection

liming

Pressure

Consumption load)

Riter Supply

Retum

Lines

combustion)

TUNE-UP

SPECIFICATIONS

478.5

435.0 Intake Intake

Exhaust

60.0 2537 Idle:

Cruise: Maximum:

FUEL

Open No.2 Mechanical Bosch Direct 60

mm

2537.5

0.46

Primary 1/4

in.

5/16

27.7

psi

(33.6

kg/cm')

psi

(30.6

kg/cm')

45°;

Exhaust

0.008

in.

(0.2

O.OOS

in.

mm

BlDC

static

psi

(178.3

kg/cm')

1000 2000 -2500 2900 -3000

SYSTEM

flow,

self-priming,

diesel

oil,

cetane

1.6

ft.

type

Injection

BTDC

static

psi

(178.4

U.S.

gaL/hr.

replaceable

(6.35

mm)

in.

(7.94

mm)

cfm

(0.78

cmm)

standard minimum

45°

mm)

(0.2

mm)

-1200

rpm rpm rpm

seH-bleeding

rating

of

(0.5

m)

lift

max.

kg/cm')

(1.76Iiterlhr.)

filter

1.0.

minimum

1.0.

maximum

45

or

higher

Electrical

System

Battery

Charging

Alternator Starting

Motor

Cold

Cranking

General

Gear

Ratio

(optional)

Propeller

used

the

engine

to

at

full

gear,

Shaft of

reach

open

underway

Ruid

Sump

Rotation

rpm

forward

lubricating Transmission

Capacity Propeller

Direction

ELECTRICAL

12 circuit

30

with

12

Amps

60

TRANSMISSION

HURTH

hardened multiple

2.05:1

rated

in

14 140 x 6 P

ATF-

0.37

Right

must

throttle

allow

its

SYSTEM

volts

DC,

negative

breaker

protected

amp,

12

volts,

solid

state

intemal

volt

solenoid,

amps@66°F

HBW

40

helical

disc

clutch

Dx8

Ptwoblade-RH

three

type

A

or

DEXTRON -/I

qts

(0.35

liters)

hand-standard

ground,

belt-driven,

regulator

actuated

shift

(19°C)

Standard

gears,

with

blade -RH

transmission

Transmission,

a

servo-operated

or

case-

11/

Engines & Generators

6

11A·1

CYLINDER

HEAD

DIESEL

ENGINE

PARTS

IDENnFICATION

fOAArpoc

CIRCUIT

BREAKER

TIlANS""SSION

OIPSTIClCIFlll

FUEL

COOlANT

TE"'PERATURE

SWITCH

STARTER

INJECTOR

TlfROTrtE

CONTROL

'TRANSMISSION

FUEL

FILTER

PREPARATIONS

FOR

INITIAL

START-UP

DIESEL

Use use

Care

Use

your which finished

The

improper

tank

well-known good, the

Fuel

If

an fuel instructions).

STA-BIL

ENGINE

FUEL

No.2

diesel

kerosene

of

the

only

clean

fuel

injection

might

parts.

best

fuel

storage

for

your

Coast

fuel

tank

Additives

fungus

or

authorized

biocide

is

OIL

A

CAUTION:

to"

without

fill

with

the

fuel

or

home

Fuel

diesel

pass

It

is

can

facilities.

engine's brand Guard

and

the

bacteria

dealer

to

sterilize

Use a fuel

an

example

lubricant

proper

with a cetane

heating

Supply

fuel!

pump

is

through

important

become

daily

of

fuel.

approved

engine.

is

causing

correct

the

stabilizer

of

This

engine

rating

fuel.

The

clearance

very

critical;

the

filter

can

to

buy

clean

unsatisfactory

To

assure

that

use

is

clean

Also

install

fuel

filter/water

fuel

problems,

these

problems.

fuel

(follow

on a regular

such a product.

was

shipped

in

the

engine.

oil.

of

45

or

of

the

invisible

damage

and

these

fuel,

and

by

careless

the

fuel

and

pure,

regularly

separator

you

Then

the

manufacturer's

basis

Before

higher.

Do

components

dirt

particles.

finely

keep

it

handling

going

into

purchase

service

between

should

have

use a diesel

as

well.

from

the

fac-

operating,

not

in

clean.

or

the

a

PRE-START

Before

starting

lay-up,

check

D

Check max.

D

Turn ine

D

Check

D

Check and battery negative

(this

D

Open ply

D

VIsually parts, threaded

D

Make connections

Make

D

These

D

Make

D

Make transmission.

INSPECTION

your

the

following

the

engine

and

min.

on

the

fuel

the

fuel

filter/water

the

transmission

the

DC

battery

cable

is

(-)

cable

location

reaches

is

the

raw

the

examine

disconnected

connections.

sure

the

are

sure

there

are

necessary

sure

the

sure

the

engine

oil

level.

marks

on

supply,

electrical

connections.

connected

is

connected

tagged).

water

intake

raw

water

the

engine.

wires,

exhaust

tight

is

good

for mounting propeller

for

the

items:

The

the

dipstick.

then

check

separator

fluid

level.

system.

to

the

and

strainer.

Look

and

Check

for

system

ventilation

proper

installation

shaft

is

first

time,

oil

level

the

fuel

bowl

for

Inspect

Make

certain

starter

solenoid

to

the

engine

make

sure

for

loose

unattached

fuel

leaks.

is

secure

and

engine

performance.

is

secure.

securely

or

after a prolonged

must

be

between

supply

and

contaminants.

wire

connections

the

positive

and

ground

the

raw

water

or

missing

hoses.

Check

all

the

an

ample

air

attached

to

the

exam-

(+)

the

stud

sup-

the

supply.

the

Use

an

engine

oil

with

an Change tion, recommended

the

engine

oil

after

and

every

100

hours

oil

viscosity,

Operating

Above 41°

-68° F

Below

A

CAUTION:

engine additives produce

TRANSMISSION

Use

ATF

The

transmission

Temperature

68° F (20°

(5° -20"

41° F (5°

C)

oil

to

mix.

of

different

properties

type

A

or

C)

Do

Each

hannful

FLUID

Dextron

sump

API

an

of

operation

see

not

allow

brand

brands

II

capacity

classification initial

50

hours

thereafter.

the

following

SAE

30,

SAE

20

SAE10W-30

two

or

contains

could

react

to

your

engine.

or

ill

transmission

is

0.37

qts.

of

CF

or

of

break-in

For

chart:

Oil

Viscosity

10W-30

or

10W-30

more

brands

its

own

in

the

lubricating

(0.35liters).

CG-4.

opera-

15W-40

of additives; mixture

to

fluid.

Engines & Generators

8

STARTING/STOPPING

PROCEDURE

ELECTRIC

The

7A-I/llA-1

engine switch

NOTE:

LOCKEZE

OIL/WATER

ALARM

Electric

1.

Place trol

A

tral.

your

STARTING

is

started

has

three

Periodically

to

ensure

Starting

the

transmission

to

slightly

CAUTION:

Starting

transmission,

diesel

engine

by

using a keyswitch

positions:

OFF,

lubricate

proper

ALARM

keyswitch

has a 12

the

VDC

electric

on

the

control

ON

and

START.

keyswitch

~~~~E~T

mechanism

functioning.

\\

\-.......-I+-

starter.

panel.

with

HOUR

METER

KEYSWITCH

The

W[g~lf'[grtl&&c:.r[g

CONTROL

PANEL

Procedure

in

neutral

and

open.

in

Make

gear

your

certain

could

boat,

the

result

and

advance

transmission in vessels

serious

nearby.

the

throttle

is

in

damage

con-

neu-

to

NOTE:

nOf77Ul1 this

2.

The

electric

device

1.

Place trol

to

Using a IOmm device (see

illustration).

POINTER THE

MANUAL STARTING PosmON

3.

Turn

the control The

pointer automatically will

stop after 8 cranks. until

either crank. ON

position.

Automatic

is

in

the

transmission

slightly

so

the

IN

,-T-t----,L.~..,.::,

keyswitch

panel

at

Then

starting.

the

operating

open.

wrench,

pointer

will

beep

on

the

move

the

9 o'clock

Hold

the

engine

let

go

Decompression

During

engine

(9 o'clock)

in

neutral

and

turn

the

hex-head

is

in

the

manual

-;-t---;i-H-_

to

the

START

until

the

engine

Automatic

clockwise

the

of

position

keyswitch

starts

the

key

or

Decompression

with

the

and

Device

operation,

position.

advance

starting

position.

oil

each

and

compression

in

the pointer it

will

spring

is

not

the

bolt

on

position

HEX-HEAD

The

pressure

Device

crank.

START

stops

the

after

back

used

for

pointer

on

throttle

con-

the

BOLT

AUTOMATIC OECOMPRESSION DEVICE

alann

on

the

comes

up.

will

The

pointer

will

occur

position

the

8th

to

the

2.

Turn the

control

the

key engine and

NOTE:

20

seconds.

start.

Never

running.

NOTE:

condition is

reached wann-up reduce

the

Low

Battery

If

the

battery

but

not

made

by

works

by

when

manually

the

keyswitch

panel

in

and

starts,

let

spring

back

If

the

engine Wait operate

Some

unstable

should

smooth

and a load

at

a

comfortable

rpm

and

Electric

is

discharged

completely

using

the

holding

starting

to

will

beep.

turn

it

to

go

of

to

the

doesn ~ start,

for

approx.

the

starter

running

out

is

applied.

get

underway.

dead,

an

Automatic

the

exhaust

(hand-cranking)

the

ON

position.

Push

the

START

the

key

and

ON

position

limit

30

seconds

motor

may

as

the

nOf77Ul1

Allow a few

rpm

(approximately

Starting

and

too

low

attempt

at

Decompression

valve

open,

The

alann

the

key

in

to

preheat.

position.

it

will

(observe

each

while

occur

When

come

that

starting

before

repeating

the

engine

in a cold

operating temperature

minutes

1,000

Procedure

for a normal

an

electric

start

Device.

and

is

normally

the

engine.

buzzer

out

of

it

does

trial

engine.

for

rpm),

electric

can This

the

preheat

to the

is

still

the

then

be

used

on

Hold

this).

10-

This

start

device

POINTER

IN

THE

OPERATING

posmON

If

this

attempt

manual

start

by

MANUAL

When space in

case

too

installing

at

the

of

low

to

an

allow

STARTING

front

emergency

j

~

~'lIJ=======

at

an

electric

start

does

not

start

hand-cranking

the

engine,

end

to

an

electrical

will

(HAND

it

is

important

allow

for

or

when

start.

be

necessary.

CRANKING)

to

provide

manual

starting

the

starting

battery

the

engine,

enough

(hand

has

then

a

cranking) become

Engines & Generators

9

STARTING/STOPPING

The

upper

illustration

the

standard guide must

If

hand cranking must be done from outside the engine compartment (see lower illustration), then the standard hand-crank handle must be extended to the required length. This modification to the handle must be done by the owner.

on

be

allowed

hand-crank

the

engine.

for

shows

handle

An

room

the

distance

protrudes

additional

to

insert

2.5

the

[4.5

from

in.

(64

handle.

in.

(115

the

crank-handle

mm)

minimum

mm)]

that

PROCEDURE

POINTER

HEX-HEAD

BOLT

AUTOMATIC OECOMPRESSION DEVICE

The

engine

may

be

when

the

starting

battery

start. A manual For

easy

Automatic

Use

both

Before

using

electric

start

Decompression

start

and

safe

manual

Decompression

of

these

devices

the

hand-crank

could

Device

ELECfRlC SfAR1);

would

then

be

considerably

not

completely

NOTE:

Oil

will

dead,

be

hand-cranking.

started

has

is

possible

be

made

(see

the

electrical

might

supplied

BULKHEAD

~"L~

l=::;:::::~

~~~.I

HANDLE

by

hand-cranking

become

with a completely

starting,

when

the

Device

and

hand-cranking.

handle,

by

using

Low

Battery

power

less,

so

allow

the

to

all

the

that a discharged

too

low

engine

a

Cold

an

attempt

the

Automatic

Electric

required

start

bearing

in

an

emergency

to

allow

dead

is

fitted

Starting

at a normal

Starting

for

points

an

with

Device.

the

battery,

when

electric

battery.

an

under

start

if

or

Cold Starting Device

This

device

are

two

When

activating

To

release

NOTE:

engine

provides

positions

this

it

(see

Never

is

operating

MODEL

more

for

the

this

device,

illustration).

pull

the

or

7A-1

SHOWN

fuel

knob:

pull

move

the

Cold

Starting

when

restarting a hot

from

up

(oft)

the

speed

the

injection

and

knob

control

Device

down

lever

knob engine.

pump.

There

(activated).

(see

illustration).

down,

down

when

COLD

STARTING

DEVICE

KNOB

then

the

Automatic Decompression Device

The

Automatic exhaust by

the

pointer.

with a 10

A

CAUTION:

Device

valve

mm

to

open.

wrench.

stop

Decompression

The

device

When

setting

the

Neller

use

the

engine.

Device

has

three

pointer,

the

Automatic

works

positions,

tum

by

the

holding

as

indicated

hex-head

the

bolt

Decompression

Engines & Generators

10

Manual

To

manually

below.

When

when

the

engine

follow

all

not a factor,

A

WARNING:

moving use

starting

1.

Place trol

to

NOTE:

Make

2.

Set

the

Neutral

when

Starting

start

the

starting

must

of

the

steps,

bypass

parts.

Put

aids.

the

transmission

slightly

open.

sure

Automatic

position

the

pointer

Procedure

engine,

follow

after

cold

first

be

turned

beginning

Steps

1-3,

Always

the

(see

keep

the

transmission

in

neutral

stop

lever

Decompression

illustration).

is

in

this

STARTING/STOPPING

4.

the

nights

over

with

and

begin

hands

and

is

in

position.

procedure

or

freezing

with

Step

with

in

advance

the

RUN

Device Compression

no

1.

If

Step

and

feet

neutral.

position.

pointer

described

temperatures

compression,

cold

weather

4.

clear

of

Do

not

the

throttle

to

the

is

released

S.

is

con-

6.

PROCEDURE

Crank

the

engine

counterclockwise

times

until

the

engine

turns

freely.

handle. Set

the

manual

ing

in

this

Pull

down

this

Automatic

starting

position

position,

the

Cold

knob

when

Decompression

(see

automatic

Starting

Device

restarting a hot

approximately

Then

remove

Device

pointer

illustration).

decompression

knob.

engine.

When

will

POINTER THE STARTING PDsmDN

Note:

10

to

20

the

crank

to

the

hand-crank-

occur.

IN

MANUAl

Do

not

pull

POINTER THE PDSmDN

3.

Insert

illustration). right crank hand

IN

NEUTRAl

the

crank

hand

on

handle

in

the

~

~'lli=======

handle

into

the

crank

Standing

top

with

position

of

your

to

the

air

left

shown

right

intake

hand,

in

the

handle

of

the

crank

filter

for

support

with

the

thumb

illustration.

guide

handle,

on

(see

and

your

put

grip

your

the

left

7.

Insert

the illustration). your

right

and

grip

on

your

S.

Slowly the

engine Decompression with

each Continue starts

firing.

the

pointer

position.After

ically

disengage.

crank

hand

the

left

crank

as

crank.

to

will

handle

Standing

on

top

crank

handle

hand

in

the

engine

fast

as

possible.

Device

Compression

crank

after

As

decompression

automatically

the

engine

Then

into

the

crank

handle

guide

to

the

right

of

the

crank

of

the

air

intake

silencer

with

your

left

hand,

position

will

compression

remove

shown

in

the

counterclockwise 4 times,

The

pointer

on

automatically

will

ends

stop

starts,

the

occur

occurs

and

at

the

crank

move

after 8 cranks.

until

compression

operating

handle

handle.

COLD

STARTING

DEVICE

KNOB

(see

handle,

put

for

support

with

the

thumb

illustration.

then

the

Automatic

clockwise

the

engine

occurs,

(9

o'clock)

will

automat-

crank

HAND-CRANKING

Model7A-1

shown

CRANK

HANDLE

GUIDE

Engines & Generators

11

POINTER

IN

THE

OPERATING

POSITION

STARTING/STOPPING

PROCEDURE

Initial

Start-Up

o

Check

for

possible

o

Make

sure

the

from

the

exhaust

o

Make

certain

o

Listen

for

unusual

Check

leaks

cooling

outlet.

that

the

sounds

List

from

water

engine

and

all

the

connections.

is

discharging

is

mounted

vibrations.

properly,

securely.

outboard

9.

If

the

engine

sider

cranking

A

CAUTION:

the

engine

system

the cooling enter

filling

pump

system

the Prevent supply

through-hull

and

correcting

ing.

Remember

water

entry

Starting

Make

sure temperature. SAE

30,

lOW-30,

charged

to

has

at a higher

starting

with

Is

pumping

during

engine's

this

from

the

is

not

Under

the

lubricating

Use

oil

minimize

not

started,

speed.

Prolonged

can

result

raw

water.

raw

water

cranking.

cylinder

happening

shutoff,

cause

of

that

engine

covered

Cold

Conditions

oil

is

with

an

API

or

15W-40.

voltage

drop.

repeat

Steps

cranking

In

the

This

intervals

engIne

may

through

This

raw

once

the

exhaust

by

closing draining the damage

by

appropriate

Specification

The

the

excessive

resulting

Westerbeke's

for

battery

should

5-9

above,

without

exhaust

happen

the

raw

water

system

the

raw

exhaust

engine

from

warranty.

the

prevailing

of

CF be

and

con-

because

water

can

fills.

water

muffler,

crank-

raw

or

CG-4,

fully

STOPPING

To

stop

the

transmission

moments

stop

control

NOTE:

o'clock). An

engine

tion

(key

from

discharging

stopping

the

engine,

to

Make

if

alarm

switch

the

THE

stabilize cable,

certain

the

keyswitch

ON).

engine.

ENGINE

bring

the

in

neutral.

temperatures.

then

turn off

this

is

provided

The

is

to

remove

throttle

Allow

the

keyswitch is

left

ON,

to

warn

best

method

the

key

to

an

idle

the

engine

Turn

the

keyswitch

is

in

the

battery

the

operator

of

preventing

from

position

to

engine

at

OFF

the

keyswitch

idle

for a few

off

the

control

position

will

discharge.

of

this

the

and

using

(12

condi-

battery

after

place

the

panel.

OPERATING

Allow a few rpm

(approximately

underway.

A

CAUTION:

down

minutes

when

THE

the

engine

Never

ENGINE

for

the

engine

1500

rpm),

pull

the

Is

operating.

then

to

wann

reduce

cold

up

at a comfortable

the

rpm,

starting

and

get

dellice

A

automatic under

Check

12

because into

the proper the

possibility

After

shutdown,

leaks

from

knob

Engines & Generators

CAUTION:

Neller

decompression

a full

load.

the

lube

oil

level a few

lube

oil

from

the

oil

sump.

Disregarding

oil

level

may

lead

of

engine

carefully

all

the

connections.

stop

the

dellice,

minutes

bearings

this

to

overfilling,

runaway.

inspect

engine

after

etc.

continues

fact

the

engine.

with

or

when

stopping

and

not

causing

the

engine

the

to

drain

maintaining

overheating

Check

for

is

engine,

down

the

and

possible

ENGINE

Although test cedures break-in dependent

its Breaking-in a new

rings operation caused

Your tioning mize conditioning

1.

2.

NOTE:

condition reached

3.

BREAK-IN

your

operations

were

time

upon

initial

50

to

the

indicate

by

overloading

new

engine

operation

the

performance

Start

and

PING

PROCEDURE

while

checking

Allow idle.

Some

should

and

While speeds

idling.

engine

at followed is

required.

hours

cylinder

carefully,

stop

the

engine

unstable

the

using

for

the

PROCEDURE

has

experienced a minimum

the

factory

to

and

that

The

how

the

engine

of

use.

engine

basically

walls.

Excessive

that

the

cylinder

the

engine

requires

abate

propeller

the

to

break-in

and

the

engine

that

to

vessel,

first

approximately

service

keeping

section.

all

systems

warm

running

as

normal

load

run

25

hours.

make

sure

the

engine

service

is

operated

involves

walls

during

each

moving

life

in

mind

according

Run

are

up,

preferably

may

occur

operating

is

applied

the

engine

Avoid

ENGINE

accurate

operated

life

of

your

and

seating

oil

consumption

are

scored,

the

break-in

50

hours

part

of

the

engine.

the

following:

to

the

STARTINGISTOP-

the

engine

functioning.

by

in a cold

temperature

at

various

prolonged

BREAK-IN

of

one

assembly

properly,

engine

serviced

the

piston

and

which

period.

of

initial

in

order

to

Perform

at

fast

running

engine.

engine

periods

hour

pro-

a

is

during

smoky is

condi-

maxi-

idle

at

fast

This

is

of

this

PROCEDURE

4.

Avoid

rapid

acceleration,

S.

Use

caution

not

grey

or

black

its

full

rated

speed

6.

During

the

second

varying

engine

Avoid

prolonged

Break-In

Monitor

o

Also items

The procedures

Check

the

following

Check

for

fuel,

Check

for

abnormal

and

blow-back Confmn When When

When

the

exhaust

the

engine

the

engine

the

engine

see

the

DAILY

to

check

each

MAINTENANCE

to

follow

Transmission

See

the

HURTH

break-in

information

to

exhaust

speeds,

List

engine

sounds.

OPERATION

day.

Break-In

HBW

especially

overload

and

are

signs

25

hours,

with

idling

during

oil

noise

smoke:

is

cold -white

is

warm -almost

is

overloaded -some

SCHEDULE

after

the

TRANSMISSION

on

your

with a cold

the

engine.

the

inability

of

an

overload.

the

engine

short

runs

this

break-in

the

50

hour

and

water

leaks.

such

as

knocking,

smoke.

smokeless.

CHECKllSTfor

section

50

hour

break-in

section

transmission.

The

presence

of

the

may

be

at

full

period.

break-in

black

gives

period.

engine.

engine

operated

rated

rpm.

period:

friction,

smoke

additional

the

maintenance

of

this

manual

of a

to

reach

at

vibration

and

soot.

for

DAILY

Start

STARTINGISTOPPING

instructions tion maintenance

SCHEDULE.

Daily

Follow

o o

o o o o

o

OPERATION

and

stop

the

engine

given

during

the

first

is

performed

Operation

this

check

Record

the

hourmeter

relate

to

the

maintenance Visually Check Check Check Look

bowl. Check

mounting

inspect

the

oil

the

transmission

your

for

clean

for

loose

is

level

diesel

secure.

in

the

50

Check

list

each

the

fuel

wires

according

PROCEDURE

ENGINE

hours

BREAK-IN

of

operation.

according

List

day

before

reading

in

schedule).

engine

for

fuel,

(dipstick).

fluid

level.

supply.

in

the

fuel

filter/water

at

the

alternator

to

the

instructions

section.

Make

to

the

MAINTENANCE

starling

your

log

oil

or

and

DAILY

given

Also

follow

PROCEDURE

sure

all

periodic

your

engine.

(engine

hours

water

leaks.

separator

make

transparent

sure

its

OPERATION

o

Check

the

o

Check

in

the

o

sec-

After

o

Transmission

See section.

drive

Check secure.

starting

Check blowby

Confmn When

the

When

the

When

the

Make

sure

from

the

DAILY

the

for

sounds.

exhaust

engine

exhaust

OPERATION

starting

belt

for

raw

water

engine,

abnormal

smoke:

engine

is is

engine

is

the

cooling

outlet.

batteries

(weekly).

wear

and

proper

pump

to

make

check the

noise

cold -white warm -almost overloaded -some

water

in

such

the

HURTH

following:

as

knocking,

smoke.

is

discharging

tension

sure

its

mounting

smokeless.

black

properly,

HBW

TRANSMISSION

(weekly).

vibration

smoke

and

is

and

soot.

outboard

Engines & Generators

13

In

order

to

log

your

record

your

NOTE:

Many

simple

but

/awwledge

use

this

Maintenance

engine

hours.

engine

hours

of

the

following maintenance

others

are

of a service

Use

by

more

difficult

mechanic.

Schedule,

your

running

MAINTENANCE

engine

time.

and

may

it will be

hounneter or

procedures

require

necessary

are

the

expert

SCHEDULE

A

WARNING:

while

the

engine equipment COrtect

tenninals

electrical

tools

when

equipment.

such

for

Never

is

running.

as

goggles

each

job.

servicing

attempt

Wear

and

Disconnect

any

of

to

perfonn the

gloves,

the

engine's

any

proper

and

use

the

battery

service

safety

the

DC

COMPONENT

Engine

oil

level

Engine

oil

change

Crankcase and

Fuel Fuel

separator

Fuel Fuel

Fuel

Raw

intake

Thermostat

Engine Air

Exhaust

Starting and batteries

DC

oil

strainer

supply filter/Water

lift

pump

filter

injector·

water

pump

water

strainer

hosas

intake

filter

system·

batteries

house

Alternator

MAINTENANCE

AFTER

ARST

50

HOURS

DAILY

OR

EVERY

8

HOURS

WEEKLY

EVERY EVERY EVERY EVERY

HOURS

•

• •

•

• •

•

100

•

FREQUENCY

3IJO

HOURS

600

HOURS

•

1000

HOURS

EVERY

2000

HOURS

•

MAINTENANCE

Oil

level

should

be indicating necessary.

Change

the

under

LUBRICATION

Remove

the

diesel

fuel.

proper

lube

Check

the

Check

for

and

replace

Clean

or

replace

LIFT

PUMP

Change

the

Check

and

sure

and

spray

FUEL

INJECTOR

ADJUSTMENTS).

Remove

the

impeller,

gaSket,

the

bearings

not

wobble).

See

RAW

COOLING

Check

the

THERMOSTATunder

Hoses

should

and

spongy. Clean. Inspect

for operation. Check

the

carbon

and/or

sages;

clean

A

defective

cause

carbon

Check

electrolyte

tions

are

very

sian. Check

the

mounting

between

marks

on

oil:

see

CHANGING

oil

strainer

Flush

the

oil.

fuel

supply.

water

and

the

filter

the

under

FUEL

filter.

adjust

the

condition

under

pump

cover

cam

and

seals

lubricate

WATER

INTAKE

SYSTEM.

functioning

be

hard

Check

and

leaks.

Check

that

exhaust

manifold/exhaust

corrosion

and

replace

exhaust

manifold/exhaust

monoxide

levels

tight.

Clean

DC

charge

bracket;

tighten

the

SYSTEM

crankcase

dirt

if

two

and

(the when

of

COOLING

and

all

from

DESCRIPTION

the

full

dipstick.

and

Top

in

necessary.

filters.

SYSTEM.

injection

(see

ENGINE

and

cover

shaft

STRAINER

the

tight.

tighten

the

connections

buildup as

leakage!

and

off

the

electrical

and

Top

THE

OIL

clean

it

with

the

up

if

necessary.

the

fuel.

Drain

See

FUEL

opening

TESTING

inspect

the

for

wear.

can

tum,

reassembling.

under

thermostat;

SYSTEM.

Replace

all

hose

clamps.

anti-siphon

are

elbow

on

inside

necessary.

make

Warning:

elbow

sure

connec-

excessive

corro-

alternator.

connections.

low

up

if

pres-

THE

Check

but

see

if

soft

valve

tight.

for

pas-

can

Check

·Westerbeke

recommends

thai

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

14

(continued)

MAINTENANCE

SCHEDULE

COMPONENT

Drive

belt

Starter

motor"

Adjust

engine

idle

speed

Valve

clearances"

Cylinder compression"

Cylinder head

nuts

Transmission fluid

level

Engine

transmission

damper

plate

Throttle

and transmission control

cable

Visual

inspection

Hardware ings connections

Cleaning

engine Lubricate

control keyswitch

and

electrical

panel

fasten-

the

AFTER FIRST

50

HOURS

DAILY

DR

EVERY

8

HOURS

MAINTENANCE

WEEKLY

EVERY

100

HOURS

FREQUENCY

EVERY

300

HOURS

•

• •

•

• •

•

EVERY EVERY

600

HOURS

1000

HOURS HOURS

•

EVERY

2000

MAINTENANCE

Inspect

for

(10

essary.

DRIVE ADJUSTMENTS).

Check sian. lubricate

Adjust Adjust

CLEARANCE ENGINE

Check

ENGINE

Retorque

CYLINDER MENTS).

Initial

300

Chattering cation replace.

Check Lubricate

Check

Inspect ble

and

Keep and cool.

Lubricate

100

check

proper

-12

mm)

deflection,

Check

belt

BELT

ADJUSTMENT

the

solenoid

Remove

and

the

starter

to

1000 - 1200

the

valve

ADJUSTMENT

ADJUSTMENTS.

the

compression

COMPRESSION

ADJUSTMENTS.

the

nuts

HEAD

fluid

change

hours

or

at

idle

of

damper

for

loose

fittings,

with

WD-40

for

oil,

fuel

and

tighten

screws,

bolts

electrical

connections.

the

engine's

oil

will

inhibit

with

for

smooth

LOCKEZE

or

at

winterizing.

hours

clearances -see

under

winterizing.

and plate

and

surface the

operating

DESCRIPTION

tension:

3/8

and

edges

and

lubricate.

motor

(see

at

all

adjust

for

wear

under

motor

for

Clean

pinion

rpm.

under

pressure -see

TEST

TIGHTENING

ENGINE

25

hours,

low

rpms

wear.

Remove

cotter

pins,

or

equivalent.

water

leaks

fastenings

nuts.

Inspect

clean.

engine's

ability

or

equivalent

After

of

the

-1/2

in.

if

nec-

(see

ENGINE

corro-

and

drive.

VALVE

under

THE

ADJUST-

then

every

is

an

indi-

and

etc

.

and

accessi-

all

wiring

Surface

dirt

to

remain

every

lubricating,

switch.

"Westerbeke

recommends

that

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

15

EXHAUST

SYSTEM

DESCRIPTION

It

is

important flooding. entering angle

of

by

Westerbeke's

knowledge Westerbeke

in-line

engine's

back

down

the

system exhaust exhaust

A

has a poor

the

engine

A

and

the

carbon

on

your

location.

For

more

Westerbeke's

and

GENERATORS,

Westerbeke

is

familiar

tem

will proper diesel which

to

install a proper

The

system

the

exhaust

line

the

vessel's

hull.

warranty.

of

marine

recommends

muffler.

CAUTION:

exhaust

the

so

there elbow hose

must

The

in-line

elbow.

exhaust

is

and

the

be

An

gradient

when

it is

WARNING:

free

of

leaks.

Monoxide

cabin

bulkhead,

information

INSTALLATION

presumes

with

the

safeguards a water-cooled

provide

for

exhaust

system

engine,

and

possibly

the

unit

is

installed.

exhaust

must

be

designed

under

any

Exhaust

The

installer

installation

installing

muffler

It

must

line

after

an

adequate

through-hull

certified

for

exhaust

can

cause

shut

off.

The

exhaust

Exhaust

waming

or

about

exhaust

MANUAL

Publication # 43268.

that

the

installer

the

engine.

can

result

to

sea

conditions

system

should

requirements.

an

exhaust

should

accumulate

the

engine

drop

in

discharge

marine

line

that

water

system

gasses

in

are

decal

50me

system

of

Failure

in

catastrophic

in

the

sinking

system

prevent

failures

be

located

any

is

shut

the

line end

use.

is

too

to

retum

must

deadly.

near

other

design,

for

MARINE

this

marine

to

design

to

avoid

engine

water

from

and

at

any

are

not

have a basic

system

having

below

water

that

down.

between

of

the

line.

long

and/or

back

be

tight

Display

your

engine,

prominent

see

ENGINES

diesel

exhaust

and

layout

damage

of

the

to

vessel

covered

an

the

runs

Design

the

The

to

engine

sys-

a

the

in

EXHAUST

Carbon

The

best inspection around

welds. nearby surrounding the

situation appearance ately by a qualified

A

Monoxide, Monoxide and can

SYSTEM

Monoxide

protection

of

the

exhaust

Make

vessel.

and

have

WARNING:

death. include:

-

Dizziness -Throbbing

against

the

complete

manifold/elbow,

sure

there

Make

sure

areas

excessively.

immediately.

of

the

exhaust

the

exhaust

mechanic.

Exhaust

an

odorless

is

pOi5Onous

Symptoms

-Nausea

-

Headache -Weakness

-

Vomiting

IF

YOU

OR

ANYONE

SYMPTOMS,

If

the down Do

not

and

repaired.

Carbon

A

carbon Westerbeke. bulkhead,

BET

OUT

symptoms the

restart

persist,

engine

the

and

Monoxide

monoxide

Display

or

in

some

engine

warning

this

other

PRECAUTIONS

carbon

monoxide

exhaust

system.

exhaust

are

no

fumes

entering

the

exhaust

lines

If

excessive

If

you

notice a change

system,

shut

down

system

inspected

gasses

and

of

carbon Monoxide

-

Muscular

-Inability

ELSE

EXPERIENCE

lITO

seek

rentilate

until

Warning

decal

prominent

contain

colorless

can

cause

In

Temples

Twitching

and

Sleepiness

to

Think

FRESH

AIR

medical

the

area

it

has

Decal

has

been

near

your

location.

gas.

ANY

been

engine,

poisoning

Check

hose,

your

are

not

heat

the

and

for

leaks

gaskets,

boat

heating

is

present,

in

the

engine

repaired

is a daily

and

from

a

the

correct

sound

or

immedi-

at

once

carbon

unconsciousness

exposure

Coherently

OF

THESE

IMMEDIATELY.

attention.

with

provided

Shut

clean

air.

inspected

by

on

your

cabin

Siphon-Break

For

installations

to

or

below install a siphon-break elbow.

The

cooling

system

tem

and

SIPHON-BREAK

information.

A

CAUTION:

exhaust

will

result

ble

flooding

where

the

vessel's

siphon-break

to

the

engine's

elbow

in

raw

of

the

waterline,

in

prevent

cylinder

in

the

Fal/ure

is

located

water

the

boat.

water-injected

provisions

the

raw

water

supply

provides

raw

COOUNG

an

air

water

from

when

the

engine

SYSTEM

to

use a siphon-break

at

or

below

damage

to

the

exhaust

vent

filling

the

engine

elbow

must

hose

in

the

is

shut

section

load

is

close

be

made

to

the

exhaust

raw

water

exhaust

down.

for

more

when

waterline

and

possi-

to

sys-

See

the

Engines & Generators

16

WARNING

Engines

Produce

Regular

CARBON

Maintenance

t:5i!EJWI!STE1IBEICE

En,.-..GMemcn

CARBON

WARNINO

MONOXIDE

Required

MONOXIDE

DECAL

EXHAUST

SYSTEM

Carbon

It installed

manufactured able

is

extremely

at

your

Monoxide

important

in

your

boat's

for

the

marine

Insulation

Inspect

insulated

deterioration

of

the

portions

Overcranking

A

CAUTION:

the

engine

starting

tem

filling

with

the

pump

is

pumping cooling enter fills.

water muffler, engine resulting

Westerbeke's

system

the

engine's

Prevent

supply

this

through-hull

and

correcting

cranking.

from

warranty.

Detectors

that a carbon

living

marine

supplier.

of

insulation.

Prolonged

can

raw

water.

raw

during

cranking. cylinder from

Remember

raw

water

monoxide

and/or

sleeping

industry.

the

result

happening the

entry

exhaust

cranking

in

This

may

water

through

once

shutoff,

cause

that

is

They

system

the

This

the

by

draining of engine

not

detector(s)

quarters.

are

inexpensive

to

ensure

intervals

engine

exhaust

happen

the

raw

water

exhaust

closing

the

excessive

damage

covered

be

Make

and

there

without

sys-

because

water

can

system

the

raw

exhaust

by

sure

is

it

is

avail-

no

Engines & Generators

17

DESCRIPTION

The

lubricating

pump.

The

pump,

which

lubricating

sump

to

The

gear-driven

oil

is

pumped

only)

to

The

piston,

lubricated.

Crankcase/Oil

for

maintenance integrated maintenance-free.

system

engine

oil

drives

points

in

repeat

the

continuous

oil

through a spin-on

the

main

bearing cylinder There

is

Strainer

information. A crankcase

into

the

cylinder

the

pump

liner

an

is a pressure

is

drawn

from

oil,

under

engine.

cycle.

is

built

and

connecting

and

rocker

oil

strainer

in

the

MAlNIENANCE

head's

feeding

the

pressure,

The

oil

into

the

type

oil

arms

in

the

inlet

LUBRICATION

system

using

an

oil

sump

by

the

oil

through

the

various

then

returns

to

the

oil

sump.

The

filter

(Model

IIA-I

rod

bearing.

are

splash-

crankcase

breather

channel

(see

SCHEDULE

valve

is

and

is

SYSTEM

ENGINE

Use a heavy or temperature. following

CG-4

OIL

or

better.

chart:

duty

For

the

OIL

Model

engine

oil

The

SAE

recommended

PRESSURE

with

grade

11A-1

an

depends

oil

SWITCH

silo

API

..

classification

on

the

viscosity,

ambient

see

the

of

CF

SPIN-ON

Model

11A-1

BREATHER

VAlVE

OIL

FILTER

only

-H--t--

Operating

Above

41° -68° F (5° -20°

Below

A

CAUTION:

engine additives

to

produce

CHECKING

Check

the

continuous Check

the because into

the

proper

oil

engine

runaway.

If

a

top-up

prevent

68° F (20"

41° F (5°

oil

to

of

different

properties

THE

lube

operation,

lube

oil

sump.

level

is

necessary,

dirt

from

Temperature

C)

mix.

oil

from

may

C)

C )

Do

not

allow

Each

brand

brands

harmful

OIL

level

(see

check

level a few

the

bearings

Disregarding

lead

to

overfilling,

clean

entering

the

SAE SAE

SAE10W-30

two

contains

could

to

your

illustration)

the

oil

level

minutes

etc.

this

fact

the

area

engine.

Oil

Viscosity

30,

10W-30

20

or

10W-30

or

more

its

react

in

engine.

prior

to

daily

or

after

stopping

continues

and

not

overheating

around

the

or

15W-40

brands

of

own

additives;

the

mixture

starting.

maintaining

With

every 8 hOUTS.

the

engine

to

drain

down

the

and

oil

filler

to

Oil

Pressure

There

is exceeds of

the

oil

maximum

Low

Oil

A

low

oil switch's oil

pressure

pulsating

Relief

an

oil

pressure

the

maximum

returns

specified

Pressure

pressure

sensor

monitors

fall

below

aIarm

on

to

the

value.

alarm

the

Valve

relief

specified

sump,

Alarm

switch

the

specified

control

valve

in

value,

keeping

Switch

is

located

engine's

panel.

the

oil

value,

sump.

If

the

valve

the

oil

pressure

on

the

pressure.

this

switch

engine

the

oil

opens

block.

Should

will

pressure

and

some

below

This

the

engine's

activate

its

a

Engines &

18

Generators

WBE

OIL

Model7A-1

DIPSTICK

$lion

LUBRICATION

SYSTEM

CHANGING

Change

every

100

the

engine

Always emulsion condition ous

damage.

the

oil.

the

exhaust

raw

water filling an

anti-siphon

A

THE

the

oil

after

hours

of

is

warm.

observe

the

indicates

is

rare,

Call a qualified

Raw

water present

system

through

the

engine.

valve,

CAUTION:

contaminants. and

nails

thoroughly discard used

Removing

1.

clothing

oil

Remove

open

end

properly.

the

oil

spanner.

OIL FILLER

CAP

OIL

an

operation

used

the

presence

it

does

attached

the

raw

This

its

Used

Avoid

Dr

Old

filler

initial

50

thereafter.

oil

as

it

of

require

prompt

mechanic

in

the

to

the

water

problem

poor

location

engine prolonged using

soap

rags

containing

Oil

cap

(see

hours

of

break-in

Change

is

removed. A yellow/gray

water

in attention should

oil

can

be

engine

and/or a siphoning

cooling

circuit

is

often

caused

or

lack

oil

contains

skin

contact.

and

used

illustration)

the

oil.

water

the

result

into

by

of

maintenance.

harmful

water.

oil.

using a 13

operation

oil

Although

to

prevent

the

Clean

Launder

Discard

only

be

present

of a

exhaust,

absence

mm

and

when

~,l«<ll--\lrll

this

seri-

in

fault

in

of

Modal7A-1

Changing

skin

Dr

When

removing cleaner, filter

to

drain

This

helps

should

be

NOTE:

Do

make

certain

Place

some unscrewing fluid

on

your

engine

make

sure

filter.

If

bracket,

the

Oil

the

to

punch a hole

the

oil

to

lessen

helpful

not

punch

it

can

paper it

to

catch

the

engine

clean.)

that

the

this

rubber

gently

rem~ve

REMOVING

Filter

used

from

spillage. A small

in

removing

this

be

towels

reduces

Inspect

rubber

sealing

_

THE

(Model

oil

filter,

in

the

upper

it

into a container

the

hole

without

removed.

and a plastic

any

oil

left

the

engine's

the

sealing

gasket

it

OLD

you

old

in

old

oil

gasket

remains

11A-1

OIL

only)

may

fmd

and

lower

before

automotive

oil

filter.

first

loosening

bag

around

the

filter. cooling

filter

as

comes

sealed

--==-

~l"~

Model

it

helpful,

portion

removing

filter

the

(Oil

or

ability.

it

is

removed

off

with

against

11A·1

of

wrench

the

filter

any

Keep

the

and

the

filter

when

other

to

old

the

old

it.

to

oil

filter

2. Model7A-I:

plug

(see

illustration),

pletely

drain

clean

the

lube

oil

change.

drain

plug.

ModelIM-I:

cover

plate

completely

the

cover

plate.

at

every

oil

below).

NOTE:

With

be

pumped

crankcase.

Place a suitable

then

the

used

oil

strainer.

After

cleaning,

Place a suitable

(see

illustration),

drain

the

used

NOTE:

change

(see

an

inclined

out,

otherwise

container

remove

into

the

Always

replace

container

then

oil

into

Be

sure

Changing

engine

too

much

below

the

oil

drain

container.

clean

this

the

strainer

below

remove

the

container.

to

change

the

Spin-On

installation,

oil

would

the

plug

Then

strainer

and

the

cover

Then

the

spin-on

Oil

the

lube

remain

oil

drain

and

remove

at

every

the

oil

drain

plate

replace

oil

Filter,

oil

in

com-

and

filter

must the

SPIN-ON

Model

When

installing

sealing

surface

clean

engine

the

filter

fmnly

NOTE:

standards be

entirely

filter

change

sure

is

normal

filter.

OIL

FILTER

11A·1

only

oil

onto

the

by

Generic

or

diameters

different

and

JW

the

new

oil

on

the

bracket

to

the

rubber

threaded

hand.

filters

are

of

important

from

genuine

oil

fill,

run

and

that

there

filter

element,

free

of

gasket

oil

filter

nipple

not

recommended,

parts.

the

engine

are

no

0

wipe

oil

and

on

the

and

items

on

Immediately

to

make

oil

leaks

the

filter

apply a thin

new

oil

filter.

then

tighten

as

the

generic

sure

around

gasket's coat

Screw

the

material

parts after

an

the

oil

the

new

of

might

oil

pres-

oil

Engines & Generators

19

LUBRICATION

SYSTEM

Adding

1.

2.

3.

TESTING

Before dipstick.

1.

the

Add

the

Replace much

force

After

refilling

Make

sure

new

oil

check

the

not

over

require

testing,

Remove

new the

filter

the

additional

THE

New

011

oil

through

oil

filler

otherwise

with

there

is

(ModelllA-l

quantity

MAX

OIL

make

the

oil

pressure

the

oil

fill.

cap.

When

tightening

the

plastic

plug

new

oil,

run

the

no

leakage

around

only),

of

oil

with

the

mark

on

the

dipstick,

oil.

PRESSURE

sure

the

oil

level

switch

(see

may

engine

the

then

stop

lube

oil

should

is

at

the

illustration).

it,

do

break.

for a few

oil

filler

the

engine.

dipstick.

the

MAX

not

use

moments.

cap

Fill

engine

mark

or

Then

to,

on

too

the

but

the

2.

Install

a

mechanical

switch

hole.

3.

Warm

up

the

and

read

the

Operating

25.6 - 56.9 psi (1.8 - 4.0 kglcml)

If

the

oil

pressure

ENGINE

NOTE:

(0.3 -0.6

TROUBLESHOOTING.

The

Bar).

oil

pressure

engine,

then

gauge.

oil pressure (engine hot):

is

too

low,

oil

pressure

switch

set

the

see

closes

gauge

engine

Low

in

the

speed

Oil

Pressure

at

4.3 -8.7

oil

pressure

at

3000

under

psi

rpm,

Engines & Generators

20

RAW

WATER

The

engine

is

designed

operates The

pump cooling river)

The

tee

the around engine. manifold/elbow, up also flowing stat

the

discharged

with a raw

raw

water

that

is

gear-driven

water

directly

through a hose.

raw

water

directs

some

remainder

the

cylinder

The

flow

and

the

thermostat

occurs

after

through

to

the

exhaust

gases.

overboard

flow

to a bypass.

sure.

The

coolant

temperature

Model

7 A-I,

and

COOLING

for

water

coolant

is

created

by

from

is

pumped

of

and the

the

through

the

flow

and

through

on

the

is

at

its

is

not

thermostat

engine

manifold/elbow

This

mixture

by

the

switch

the

thermostat

SYSTEM

direct

raw

temperature

by a positive

the

camshaft.

the

raw

water

a

tee

to

passages

The

flow

the

cylinder

bypass

greatest

yet

open.

is

open.

block

then

where

of

exhaust

engine's

is

located

housing

water

source

which

in

to

the

goes

when

Flow

The

flows

it

exhaust

on

COOLING

cooling.

displacement

This

the

engine

directly

the

mixes gas

for

The

up

to

90"

pump

(ocean.

splits

the

engine

block

head,

cooling

to

engine

though

the

raw

water

through

the

with

and

raw

gas

discharge

the

cylinder

ModelllA-1.

engine

F

(32°

impeller

draws

lake

flow.

block

circulates

the

exhaust

is

warming

bypass

that

thermo-

and

water

head

or

The

and

the

is

cools

pres-

C).

is

SYSTEM

MODEL

for

lA·1

THERMOSTAT

A

thermostat, water ing

system. 140° F (60° mostat through a bypass heating). opens. or

replaced

Checking/Replacing

Remove remove

To

check

140° F (60°

this

indicates

Use a new Apply a thin pressing

Run

the

are

no

COOLANT

The

coolant housing reaches the

alarm

located

on

coolant

temperature

The

thermostat

C).

When

prevents

The

leaks

As

the

thermostat

easily.

the

two

the

thermostat

the

thermostat,

C).

the

gasket

coat

it

into

engine

at

coolant

tube

engine

Carry a spare

cap

screws

The

thermostat's

thermostat

when

of

sealant

place.

and

check

the

thermostat

TEMPERATURE

temperature

(see

illustration).

approximately

on

the

control

the

from

to

warms

is

from

reinstalling

Do

175° F (80°

top

of

the

as

the

is

set

engine

flowing

prevent

up,

accessible

the

Thermostat

and

the

cylinder

immerse

is

in

on

both

not

over-tighten

for

normal

housing.

switch

is

If

the

panel.

cylinder

coolant

flows

to

the

maximum

is

first

started,

(some

the

exhaust

the

thermostat

and

can

thermostat

the

thermostat

head

it

in

water

cone

must

good

condition.

the

thermostat

sides

of

temperatures

SWITCH

located

near

coolant's

C)

operating

this

head,

through

coolant

manifold

be

checked,

and

gasket.

housing,

(see

that

then

the

gasket

the

cap

the

switch

controls

the

is

the

cool-

temperature

closed

is

by-passed

from

gradually

cleaned,

then

illustration).

approximately

be

fully

open-

or

replacing

before

screws.

and

that

thermostat

temperature

will

activate

raw

ther-

over-

there

of

it.

MODEL

11A·1

BLEED

HOLE

THERMOSTAT HOUSING

CYliNDER HEAD

Engines & Generators

21

THERMOSTAT

ASSEMBLY

Model

7

A·1

sIIown

RAW

WATER

The

raw

water non-ferrous flexible

vanes impeller should impeller. cover

failures engine are

The

inspected

NOTE:

(seals new

Inspecting/Changlng

Close with out blades into of valve.

NOTE:

of

housing,

this

There

gasket

occur

operation.

cautioned

neoprene

S.hould a failure

and

pump

the

aid

of

the

to

the

pump's

lubricant

Never

dry

running

PUMP

pump

housing

which

pump

be

should

(an

impeller

when to

make

impeller

regularly.

bearings),

and

rebuild

raw

water

of

two

pump.

Install

conform

housing.

to

the

allow

may

is a self-priming,

and a neoprene

wipe

against a curved

producing

run

dry

always

kit)

lubricant

Such

failures

sure

raw

has

a limited

occur

it

may

the

original

the

intake

valve.

small

screwdrivers,

the

new

to

the

curved

When

impeller

the

pump

destroy

and

the

pumping

as

water

be a spare

onboard.

(raw

are

water

with

be

more

Raw

Remove

impeller cam

assembling,

gasket.

to

run

the

impeller.

rotary

impeller.

acts

impeller

Raw

water)

not

warrantable

flow

lifetime

the

pump's

cost

pump

Water

carefully

plate

Open

dry.

COOLING

pump

with

The

impeller

cam

plate

action.

On

no

as a lubricant

and

water

pump

is

not

present

and

is

present

and

must

internal

effective

as a spare.

and

Even a short

Pump

the

pump

gasket.

and

apply

the

pry

push

raw

to

purchase

the

a

thin

a

has

within

the

account

for

the

impeller

impeller during operators

at

start-up.

be

parts

a

Impeller

cover

and,

impeller

Move

the

impeller

coating

water

intake

period

SYSTEM

RAW

WATER

A

flush-type intake. below Westerbeke's

and

GENERATORS

A

fitting type and exhaust engine's into

covered

Flooding occur

its

bow

waterline

the

boat

RAW

NOTE:

the

strainer

A

clean engine's strainer the

glass

Perform of

operation:

1.

2.

3.

4.

5.

6.

7.

NOTE:

hard

If

the tures or

grass

of

raw

though-hull

It

should

the

waterline

INSTAlL4.TION

WARNING:

for

supplying

raw

water

force

water

system

cylinder.

the

engine's

by

Westerbeke's

of

the

exhaust

with a flush-type

up.

This

before

to

the

sea

WATER

Always

install

will

always

raw

water

cooling

when

making

should

be

the

following

Close

the Remove Clean

the Replace Reassemble Open

the

Run

the

Also

follow

aground.

engine

is

indicating

(i.e

the

alarm

may

have

water

through

INTAKE

fitting

be

located

on

during

all

for

complete

Do

not

use a scoop-type

raw

water

inlet

can

develop

past

the

raw

and

allowing

Damage

cylinder

wananty.

system

raw

water

pressure

the

INTAKE

system.

and

the

engine

boat

reaches

surface

the

be

intake

Include a visual

your

clear.

maintenance

raw

water

clean

glass.

sealing

and

install

seacock.

and

the

above

is

sounding),

been

caught

the

can

when

STRAINER

strainer

self-priming.

strainer

periodic

seacock.

the

washer

check

higher

cooling

is

recommended

the

boat's

hull

angles

of

the

MANUALfor

installation

to

this

substantial

water

pump.

the

water

caused

ria

due

be

strainer

procedure

the

to

intake caused its

final

its

is

at

is a vital

engine

after

if

the

strainer.

for

than

the

cause

up

in

system.

by

exhaust

water

on a powerboat

by

underway.

or

below

every

filter.

necessary.

leaks.

normal

the

for

the

raw

where

it

will

boat's

operation.

MARINE

guidelines.

ENGINES

through-hull

engine. A scoop-

pressure

flooding

to

enter

raw

water

system

pressure

the

boat's

trim,

or

by

the

component

inspection

check.

100

after

having

operating

may

be

strainer,

slowing

the

entry

is

not

can

also

that

decreased

the

angle

waterline

of

the

of

this

The

water

hours

run

tempera-

that

silt,

the

water

be

See

has

of

so

in

leaves

flow

RAW

WATER

PUMP

Engines & Generators

22

RAW

WATER

OWNER

SIPHON-BREAK

For

installations

to

or

below install a siphon-break elbow.

The

cooling

system

tem

and

where

the

vessel's

siphon-break

to

the

engine's

the

in

prevent

cylinder

INTAKE

INSTALLED

water-injected

waterline,

the

raw

water

provides

raw

water

when

STRAINER

(TYPICAL)

exhaust

provisions

supply

an

air

vent

from

filling

the

engine

COOLING

elbow

is

close

must

be

made

to

hose

to

the

exhaust

in

the

raw

water

the

exhaust

sys-

is

shut

down.

SYSTEM

THERMOSTAT HOUSING

HOSE

FROM

SIPHON-BREAK

THE

HOSE

TO

THE

SIPHON-BREAK

A

CAUTION:

exhaust will ble

If

you exhaust vessel's under to

The is waterline. during occurring.

(these

raw

siphon-break illustration). additional

NOTE:

to siphon-break siphon-break

elbow

result

In

flooding

have

any

elbow

relative

various

way,

install

protect

your

siphon-break

looped a minimum

This

all

angles

WESTERBEKE

are

tagged).

water

line

attaches

The

lengths

A

siphon-break

ensure

proper

can manufacturer

Failure

Is

located

raw

water

of

the

boat.

doubt

about

to

the

operating

engine.

siphon-break

of

at

operation.

conditions

a siphon-break.

must

be

of

20

vessel

The

hose

the

thermostat

to

the

owner

must

of

hose

that

requires

result

in

to

use

a

at

or

below

damage

the

installed

inches

operation

water-injected

Failure

severe

for a proper

position

vessel's

must

has

provided

to

the

housing.

furnish

may

periodic

engine

to

waterline

or

This

in

(51

always

to

siphon-break

be

to

siphon-break

the

engine

of

the

when

precaution

the

high

cm)

above

be

prevent

two

The

exhaust

the

siphon-break,

required.

inspection

properly

damage.

maintenance

when

load

waterline

and

water-injected under

any

the

vessel

is

necessary

point

of a

the

vessel's

above

the

siphoning

siphon-break

connects

hose

from

elbow

and

maintain

Consult

schedule.

the

possi-

of

the

is

not

hose

that

waterline

from

hoses

to

the

(see

and

any

cleaning

a

the

DRAINING

When be

drained

will

then

freezing

by

flush

THE

unscrewing

back

COOLING

temperatures

the

down

the

SIPHON-BREAK

Model

11A-1

SYSTEM

are

expected,

pump

cover.

inlet

line.

shown

the

cooling

The

raw

system

water

can

coolant

Engines & Generators

23

DESCRIPTION

The

7 A-I

and

llA-l

cruise

rpm

range,

will

feet

of air per

lated,

Air

Filter

The

air engine; quiets

Maintenance

The

fliter cartridge compressed replace

and

fliter

it

the

it.

hour.

the

air

cartridge

also

improves

engine.

should

on a flat

air.

The

flow

be

cleaned

surface

If

the

marine

typically

engine

into

the

prevents

oil

consumption,

to

cartridge

diesel

engines,

consume

compartment

engine

dust

every

100

dislodge

is

badly

in

excess

must

be

and

dirt

extends

operating

loose

dirt

contaminated

AIR

when

operating

of

must

be

unrestricted.

from

entering

engine

hours.

or

clean

INTAKE

in

the

1000

cubic

well

venti-

the

life,

and

Tap

the

it

off

with

or

oily,

FILTER

WATER

This coolant heater or

Plumb thermostat

NOTE:

below on

ING

tions

HEATER

engine

to

transfer

should

high

position

the

If

the

vessel s waterline,

the

same

SYSTEM

may

be

is

equipped

be

in

heater

housing

exhaust

hose

for

located

INSTALLATIONS

with

connections

heat

to

an

on-board

mounted

hoses

in

relation

to

into

to

the

exhaust

manifold/elbow

(see

Siphon-Break

more

information).

either

before

a convenient

the

engine.

the

raw

water

manifold/elbow

you

must

under

or after

for

plumbing

water

heater.

The

on

also

The

location

line

your

either

that

connects

(see

engine

install a siphon-break

RAW

WATER

water

heater

the

siphon-break.

WATER

the

engine water in a low

the

illustration).

is

close

COOL-

connec-

THERMOSTAT HOUSING

HEATER

to

or

FROM

WATER

HEATER

~

TO WATER HEATER

Engines & Generators

24

WATER

Model

HEATER

llA-l

CONNECTIONS

shown

DIESEL

Use use

FUEL

If

an biocide

Also Follow

CARE

Use The very filter clean tory that it approved micron engine.

FUEL

No.2

kerosene

ADDITIVES

fungus

or

authorized

to

use,

on a regular

the

OF

only

clean

clearance

critical;

can

damage

fuel

by

careless

the

fuel

properly.

fuel

rating

diesel

fuel

with a cetane

or

home

heating

bacteria

sterilize

manufacturer's

THE

and

Install

dealer

the

FUEL

diesel

of

the

invisible

these

keep

it

handling

going

to

and

filter/water

of #2

or

is correct

fuel

basis, a fuel

fuel!

components

dirt

clean.

your

fuel.

causing

fuel

these

(follow instructions

SUPPLY

Purchase

particles

fmely

fmished

The

or

improper

engine

regularly

separator

# 1

O.

Install

rating

of

45

problems,

problems.

the conditioner

in

which

best

is

service a good

having a filter

it

Then

manufacturer's

for

the

a

well-known

your

fuel

might

parts.

It

fuel

can

storage

facilities.

clean

and

between

or

higher.

you

should

use a diesel

instructions).

such

as

STA-BIL.

quantity

injection

become

the

to

brand

pump

pass

through

is

important

unsatisfac-

pure,

be

sure

Coast-Guard

element

fuel

tank

FUEL

Do

not

have

fuel

add.

of

fuel.

is

the

to

buy

To

assure

to

filter

with

a

and

the

SYSTEM

FUEL

FILTER

The

frequency contamination after

every

Replacing

1.

Clean the fuel line with a rag and clamp it off between

the

2.

Pull sure dirt does not enter the used

3. Install the new filter, making sure the

filter housing is pointed in the proper direction. fuel

of the

After

installing

using

the

SYSTEM).

of a

fuel

filter

change

of

the

fuel,

however

100

hours

of

engine

the

fuel

filter

fuel

lift pump and the fuel

off the inlet and outlet lines from

filter.

lines

as

far

as

possible onto the connection nipples

new

filter.

the

new

filter,

manual

fuel

primer

it

operation.

filter.

fuel

bleed

the

(see

BLEEDING

depends

should

on

the

be

performed

the

filter.

lines. Discard the

flow

arrow

air

from

the

fuel

mE

degree

Make

on

Push

lines

FUEL

at

of

least

the

FUEL

LIFT

To

assure

proper

more

than 1 ft

tube. Periodically

pump are

tight

A

check

and

make

and

WARNING:

connections Make

sure

fuel

system

The

fuel

lift

pump

or

replace

them,

the

two

filter

proper

reassembly.

PUMP

suction,

the

(300

mm)

above

the

fuel

sure

that

no

secure.

Fuel

leakage

is a

fire

hazard

proper

"entilation

components.

has

two

unscrew

inserts.

the

Note

engine's

the

bottom

connections

leakage

is

at

and

exists

filter

inserts

cap

and

the

disassembly

fuel

lift

of

to

and

preSent

the

fuel

should

whene"er

in

the

retaining

sequence

pump

should

the

fuel

tank

from

the

and

that

litt

pump

be

corrected.

sellficing

pump's

cap.

plate,

and

to

not

pickup

fuel

the

fittings

or

To

remove

ensure

be

OUTLET

lift

its

clean

FUEL

LIFT

PUMP

Engines & Generators

25

FUEL

LINES

The

fuel

return

bottom

of

the

tank

This

must

be

done

below

the

engine's

hard

starting

due engine's shutdown.

FUEL

Westerbeke good of be contaminants fuel

It

fuel

system

A

WARNING:

servicing that Dr servicing. servicing

may

other

the

spill.

sources

Ensure

the

FILTER/WATER

recommends

quality

Coast

the

water-separating

installed

may

on

the install or

# 1 0

Most installation contaminants

A

typical

Raycor

type engine-mounted fuel owner/operator the process

fuel

between

lift

pump

also

prolong

fuel

line.

this

fuel

micron

installers

package

fuel

Model

fIlter

is

pump,

engine

engine's

is

accomplished

fUlcr/wMer

or

and

in

fIlter/water

not

injection

FUEL

SYSTEM

FUEL

The

line

at

the

fuel

tank

should

extend

down

to

the

in

the

same

manner

as

the

fuel

pickup

tube.

in

an

fuel

to

air

fuel

DD

fuel

of

installation

system.

displacing

through

Shut

off

system.

NOT

allow

fire

near

proper

system.

where

This

precaution

fuel

siphoning

the

return

line

the

fuel

valve

Take

care

any

smoking,

the

fuel

ventilation

the

fuel

insures

when

at

in

catching

system

exists

tank

out

of

the

engine

the

tank

open

when

is

located

against

the

is

when

any

fuel

flames

SEPARATOR

that

you

install

and

regularly

Guard

approved

type.

the

fuel

water

that

may

causing

damage

the

life

of

It

is

the

responsibility

filter/water

rating.

include a fuel

the

500

installed

fuel

is

responsible

as

they

fuel

can

MA.

Keep

system,

filter

and

equipment

by

separator.

separator

between

sepmmo'·1j:~l

This

fuel

tank

and

be

in to

the

fuel

fIlter/water

are

aware

cause.

is

in

mind

the

any

water

injection

for

making

is

free

installing

\f

visual-type

fIlter/water

the

engine

the

fuel

from

the

fuel

system

fIlter

that

of

the

owner-operator

Select a

illustrated

equipment.

fIlter

separator

of

the

problems

that

if

a

fuel

supply

in

the

certain

of

impurities.

and

maintaining a proper

I

'\

.

primary

separator

to

reaching

comes

with

below.

water

tank

fuel

will

The

the

service

fuel

must

prevent

any

the

components.

installed

that

has a #2

the

This

separator

and

the

affect

fuel

reaching

This

a

fIlter

to

is

the

fuel

diesel

engine, injection owner-operator adjustment tion

pump

SPEED

requires injection and

repair

FUEL

For

information

see

TESTING

MENTS.

In

case

tors

checked

vice

center.

fuel

pressure

Since

fuel

ment,

it

a

problem

BLEEDING

The

fuel

will

bleed

done

by

illustration).

use

the

fuel

tank;

bleed

the

system Bleeding

engine of

inactivity.

To

use

slow

complete

turn;

this

action.

SPARE

While the

possibility

washers,

at

all

times.

WESTERBEKE

a

banjo

the

fitting,

the

hardware

INJECTION

injection

pump

the

is

the

ADJUSTMENT

servicing,

pump

it.

pump

requiring

has

been

is

cautioned

servicing

adjustment

remove

service

PUMP

facility.

INJECTOR

about

removing

THE

FUEL

of

severe

vibrations

and

overhauled

Poor

fuel

quality,

to

the

injection

injectors

is

best

occur.

injection

out

using

manual

it

air.

after

the

is

layed-up

the

manual

will

to

carry

THE

pump

through

the

manual

In

case

fuel

will

not

Also

changing

fuel

system

during

See

LAY-UP

fuel

strokes.

reposition

must

FUEL

the

primer

be

use

the

PARTS

the

likelihood

injector

Purchase

washer

replace

does

that

kit

of

exist.

seat

dealer

cannot

the

for

your

washers

needed

sealing

is a very

the

utmost

thoroughly

not

to

mechanic

for

engine

under

ENGINE

it

and

Do

INJECTOR

and

detonation

by

contaminants

pump

be

serviced

at

least

one

SYSTEM

is

self-bleeding;

fuel

return

fuel

primer

engine

to

bleed

necessary

the

manual

fuel

filters.

will

also

the

off-season

AND

primer,

work

If

pressure

the

fuel

having

to

Therefore,

and a fuel

spare

or

distributor.

be

corrected

washer

model.

important

care

attempt

should

take

and

an

authorized

can

extra

is

shut

to

fuel

be

RECOMMISSIONING.

pump

service

component

in

handling.

bench-tested

idle

ADJUSTMENTS).

it

to

not

attempt

checking

under

result

in a clean

injector

line.

on

down

the

system

disconnect

primer

necessary

or

the

lever

isn't

felt,

to

we

parts

If a

by a simple

with a replacement

and

to

service

make

to

speed

(see

an

authorized

to

the

ENGINE

noise,

have

fuel

and

loss

in

injector

room

as a spare

any

air

in

Bleeding

the

fuel

lift

due

to

after

the

to

bleed

before

for

prolonged

back

rotate

improve

the

system

recommend

fIlter

be

from

your

leak

should

The

the

it.

the

IDLE

disassemble

fuel

injection

of

environ-

the

can

pump

lack

refilling

fuel

and

the

at

that

carned

local

tightening

of

the

fuel

The

only

fuel

injec-

Ifit

fuel

injector,

ADJUST-

the

injec-

ser-

positive

faults.

should

fuel

lines

also

be

(see

of

fuel,

the

lines

to

the

periods

forth

with

engine

112

pumping

sea

is

slim,

banjo

on

board

develop

found

at

of

in

FUEL

Fll

TERI

WATER

SEPARATOR

(owner

installed)

Engines & Generators

26

12

VOLT

DC

CONTROL

The

engine

has a 12

shown

on

the

troubleshooting

A

CAUTION:

Ing

circuit,

while

the switch, on

the

engine's

however.

CONTROL

The

engine

is

The

keyswitch

STARTINGISTOPPING

NOTE:

Push

ON

position.

NOTE:

Periodically

maintain

The oil

The should

proper

oil

pressure/coolant

pressure

hourmeter

be

used

HOURMmR

KEYSWITCH

volt

wiring

diagrams.

or

when

To

never

shut

engine

is

to

electrical

PANEL

started

by

has

three

the

key

in

lubricate

operation.

is

too

low

registers as a guide

avoid

running.

or

CIRCUIT

DC

electrical

servicing

damage

off

the

avoid

electrical circuit.

using

the

positions:

PROCEDURE).

to

preheat

temperature

the

engine

the

elapsed

for

the

control

Refer

to

the

DC

engine

Shut

keyswitch

OFF,

after

the

keyswitch

alarm

is

overheated.

engine

maintenance

these

electrical

to

the

battery

off

the

shorts

on

ON,

turning

with

beeps

running

DC

ELECTRICAL

circuit

that

is

diagrams

battery

when

system.

charg-

switch

engine

battery

when

working

the

control

panel.

and

START

(see

the

key

to

the

WCKEZE

when

time,

schedule.

either

and

to

the

SYSTEM

ENGINE

The

mounted current panel this disconnects the breaker

BATTERY

The engine's

(CCA).

Battery

Review systematic ies

o

o o

CIRCUIT

DC

wiring

manual

draw

wiring

event

the

source

of

and

minimum

12

Care

the

maintenance

and

service

Monitor engine

Check a

hydrometer.

Use

only

Make

certain

tight

to

Keep

your

or

engine

the

restart

recommended

volt

manufacturer's

your

operation.

the

distilled

the

BREAKER

harness

on

reset

circuit electrical engine

wiring

will

fuel

supply.

problem.

the

engine.

DC

control

schedule

batteries.

voltmeter

electrolyte

water

that

battery

posts

batteries

the

engine

is

breaker

(10

overload shut

clean

anywhere

will

cause

down

because

If

this

should

After

repairing

capacity

circuit

recommendations

for

level

to

and

for

proper

and

bring

cable

to

and

is

free

of

200

your

specific

electrolytes

connections

your

protected

amps

in

the

breaker

the occur, the

fault,

the

battery

Cold

and

engine's

charging

gravity

engine.

of

corrosion.

by

an

DC).

Excessive

the

instrument

to

trip.

opened

check

and

reset

used

Cranking

then

establish

starting

during

with

to a proper

are

clean

engine-

In

breaker

repair

the

in

the

Amps

batter-

level.

and

a

Oil

PRESSUREI COOLANT AlARM

TEMPERATURE

ALARM

CONTROL

PUSH

PREHEAT

PANEL

A

WARNING:

cause

severe

protective

Checking

10

Check a

voltage not, Troubleshoot

wiring the

battery

the

between

there

and

the

voltage

is a problem

connections, itself.

burns

gear.

Service

the

service

Sulfuric

on

of

the

13

and

in

skin

Battery

service

14

volts

the

service

battery

the

solenoid,

acid

and

battery.

when

charging

in

lead

damage

This

the

battery

circuit

isolator,

batteries

clothing.

battery

engine

is

charging

by

checking

battery

can

Wear

should running.

circuit

switch,

have

If

the and

Engines & Generators

27

DC

ELECTRICAL

SYSTEM

ALTERNATOR

A

WARNING:

hot.

Do

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

The alternator charging circuit charges the starting battery and the service battery. An isolator with a diode, a solenoid or

a battery selector switch is usually mounted in the circuit

to isolate the batteries so the starting battery is not discharged along with the service battery. starting battery but not the service battery, the problem is in the

service battery's charging circuit and not with the alterna-

tor.

Testing

A

CAUTION:

that

everyone

sheaves

TROUBLESHOOTING

A failed alternator

not

touch

until

the

alternator

or

If

the

Alternator

Before

starting

is

clear

of

moving

and

belts

during

test

procedures.

can

become

has

with the'alternator.

voltage regulator

the alternator is charging the

the

engine

parts!

Keep

cooled

if

a problem

make

away

very

down.

If

is

faulty,

certain

from

it is

MULTIMETER

TESTING BATTERY (ENGINE

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

THE

STARTING

IALTERNATOR

RUNNING)

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

A

CAUTION:

charging switch

when

circuit,

the

To

avoid

never

engine

damage

shut

off

is

running!

to

the

battery

engine

battery

A

WARNING:

DC

and

AC applications. isolate

DC before

performing

made

without a proper

1. Start the engine.

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

a.

If

the voltage

tor

is

to

"Checking the Service Battery" on the next page.

b.

If

the voltage remains around 12 volts, a problem exists with either the alternator or the charging circuit; continue with Steps 3 through

When

testing

circuits

and

working; omit Steps 3 through 8 and go directly

are

Always

AC

converters, DC

is

often

disconnect a shore

testing.

knowledge

increasing toward 14 volts, the alterna-

with

mixed

and No

AC

a multi

together

power

shut

down

tests

of

AC

circuits.

8.

meter:

in

marine

cord,

the

should

engine be

4.

If

a battery selector switch is in the charging circuit,

ensure that it is on the correct setting.

5.

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

6. Check the battery voltage. tion, the reading should

TESTING

ALTERNATOR

(IGNITION

THE

VOLTAGE

ON • ENGINE

If

the battery

be

12 to

e~=~3i

OFF)

-=

GROUND

is

in good condi-

13

volts.

~--MULTIMmR

Engines & Generators

28

DC

ELECTRICAL

7.

Now check the voltage between the alternator output minal (B+) and ground. the alternator will be the same as the battery, or tor

is

in

the

circuit the alternator voltage will be zero.

neither

of

the above

between the alternator and the battery. Check all the

connections - look for an opening in the charging circuit.

If

the circuit

is

true, a problem exists in the circuit

is

good, the voltage

if

MULTIMETER

ter-

an isola-

If

at

SYSTEM

Checking

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

the

If

not, there

Service

of

Battery

the service battery. This battery should

13

and

14

volts when the engine

is

a problem in the service battery

is

solenOId,

TESTING BATTERY/ALTERNATOR (ENGINE

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

The voltage reading for a properly operating alternator should be between 13.5 and 14.5 volts. is over- or under-charging, have it repaired at a reliable service facility.

NOTE:

voltmeter to ensure that at

the EXC terminal if the previous test showed only bat-

tery voltage at the B output terminal.

If

12

wiring and

THE

STARTING

RUNNING)

Before removing the alternator

12

volts DC excitation is present

volts is not present

lookfor

at

breaks

the and

EXC

poor

-c==>-'

If

your alternator

for

repair; use a

terminal, trace the

connections.

ENGINE GROUND

MUlTIMETE.

GROUND

A

CAUTION:

do

not

use a high

performing

i

COM

tests

To

avoid

voltage

on

the

TESTING

BATTERY

damaging

tester

(i.e. a megger)

alternator

SERVICE

charging

THE

the

alternator

BATTERY

(ENGINE

SERVICE

RUNNING)

diodes,

wilen

circuit.

Engines & Generators

29

SEE

r-------------,

I

NOTE

2

:r~

l§j

I

+ I

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ELECTRICAL

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DIESEL

DIAGRAM

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SYSTEM'

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AND

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THE

IGNITION

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30

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SWITCH

NOTES

THIS

PRODUCT STARTER SHUT ENGINE

AN DISCONNECT WITH A CONTINUOUS SWITCH

DOWN.

ARE

ON·orr

SHOULD

EXCESSIVE

SWITCH

Engines & Generators

IS

PROTECTED

THE

BUILDER/OWNER

INSTALLED

SHOULD

THE

BATTERY

RATING

NOT

BE

31

BY A MANUAL

CURRENT

TO

PREVENT BE

IN

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or

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TO

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MUST

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AMPS.

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ELECTRICAL

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METER

+

LOCATED

AND

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Engines & Generators

32

REMOTE

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DC

ELECTRICAL

SYSTEM

~(-----------12

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(

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PRODUCT STARTER. SHUT

DOWN.

ENGINE

2.

AN

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DISCONNECT WITH A CONTINUOUS SWITCH

EXCESSIVE

ARE

INSTALLED

SWITCH

THE

SHOULD

IS

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CURRENT

BUILDER/OWNER

TO

SHOULD

BATTERY

RATING

NOT

BE

USED

BY A MANUAL

WILL

MUST

PREVENT

CONTACT

BE

INSTALLED

IN

AN

EMERGENCY

or

175

AMPS

TO

MAKE

CAUSE

BE

BETWEEN

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WHEN

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TO

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AND

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AND

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LOCATED

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THE

ENGINE

PANEL.

AND

STARTER

rUNCTION

NEAR

THE

WIRING.

SEAWATER.

TO

WILL

AND

THIS

Engines & Generators

33

GLOW

MODEL

PLUGS

7A-1

ONLY

DESCRIPTION

The

glow

plugs

(2)

are

PREHEAT "click"

on

is

and

pressed

the

glow

INSPECTION

To

inspect

the

plug,

remove

then

unscrew clean solution ing,

examine

much,

each

to

replace

each plug's remove

the

plug

tip

all

tip

plug.

and

for

TESTING

An

accurate

one

prod

body

0.55 out

of

drain

A

to

testing

way

to

the

glow

of

the

glow

plug,

ohm

resistance.

the

(5

engine.

- 6

amps

You

per

WARNING:

the

touch.

the

Be

plugs.

test

plug's

careful

wired

through

at

the

control

plug

should

the

electrical

from

the

threads

the

carbon

wear

and

glow

plugs

wire

as

shown. A good

This

method

can

also

plug).

These

glow

not

the

panel

begin

air

intake

with a soft

and

oil

deposits.

burn

erosion;

is

with

connection,

can

be

use

an

ammeter

plugs

to

bum

preheat this

solenoid

to

get

terminal

adapter.

brush

if

an

ohmmeter.

and

glow

plug

used

with

will

become

your

fingers

solenoid.

should

hot.

connections,

Thoroughly

and

cleaning

While

clean-

it

has

eroded

the

other

will

have

the

plug

to

test

the

very

when

When

Touch

to

the

in

power

hot

too

a

or

Re-install The

seconds.

cuit.

on

A

than

Glow plug tightening torque: 7 -

the

plugs

should

If

the

plugs

When

reinstalling

the

threads.

WARNING:

30

seconds.

in

the

air

intake

get

very

hot

(at

the

don't

heat

up

the

glow

plugs,

Do

not

keep a glow

~==-======"""",::e..

TESTING A GLOW WITH

AN

OHMMETER

adapter

terminal

quickly,

use

11

and

test

end)

within

check

for a short

anti-seize

plug

on

ft-Ib (1.0 -

PLUG

them

again.

7

compound

for

more

1.5

m-kg)

TERMINAL END

TIP

to

__

15

cir-

TESTING A GLOW USING A TEST

UGHT

PLUG

+

Engines & Generators

34

ENGINE

ADJUSTMENTS

NOTE:

be

performed

is

provided

TIGHTENING

After

the

retorque

1.

Remove

2.

Retighten the four cylinder head sequence

initial

the

THE

CYLINDER

break-in

cylinder

the

as

period

(approximately

head

nuts.

Do

this

cylinder head cover and gasket.

shown

in

the illustration. Start

Before applying the torque to a

tum, then apply the

SPECIFICATIONS

torque.

for

the proper

See TORQUE

3. Reinstall the cylinder head cover plastic washers under the two

nuts

specified torque.

VALVE

Check every

NOTE:

before

CYUNDER

Adjust

clearance

1.

2.

CLEARANCE

the

valve

clearances

600

hours

thereafter.

Tighten

the

cylinder

adjusting

the

Remove the cylinder Check

device

HEAD).

valve

is

0.2

to is

the

valve

clearances

mm

make in

its

normal

(0.008

sure

ADJUSTMENT

after

the

head

bolts

clearances

when

the

in.)

for

both

head.

the

automatic decompression

operating position,

(see illustration).

WESTERBEKE

by

to

assist

HEAD

50

when

the

nuts

in

an

nut,

loosen it

torque.

and

gasket. Insert

and tighten

first

50

hours

to

their

specified

(see

TIGlffENING

engine

is

cold.

intake

and

a

competent

the

hours),

engine

X-pattern

with

114

to

of

operation

The

exhaust

i.e.

not

recommends

engine

mechanic.

is

cold.

any

nut.

to

112

a

new

the

and

torque

THE

valves.

activated

that

the

following

mechanic.

5.

For between

engine

The

information

each

valve, insert a

the clearance until a slight pulled

out.

6.

Tighten

the

a screwdriver.

7.

Recheck

ENGINE

To

check

shut

off

the clearance.

COMPRESSION

the

engine's

the

raw install a compression pression motor

tester

until

on

the

pressure

Compression pressure

Minimum: 435.0 psi (30.6 kg/cm

Standard: 478.5 psi (33.6 kg/cm

ADAPTER

adjustments

below

0.2

mm

valve stem

and

drag

the is

rocker

felt

locknut while holding

TEST

compression

water

through-hull,

adapter

the

adapter

reaches a maximum

at

pressure,

remove

in

the

injector

and

crank

350 rpm:

(0.008

on

the

2

in.)

feeler

arm,

and

the gauge

setting

warm

up

the

fuel

hole.

Connect a com-

engine

with

value.

)

gauge

adjust

when

screw

with

the

engine,

injector,

the

it

is

and

starter

POINTER

~

="~JJ=======

3. Set the piston at

4.

Loosen the locknuts (see

illustration).

the

TDC

'---l-'H--

of the compression

on

the valve setting

AUTOMATIC DEVICE

IN

THE

OPERATING

POSITION

stroke.

screws

DECOMPRESSION

NORMAL

Engines & Generators

35

If

the

pressure related. again. into

If

the

Check

the

cylinder

compression

An

abnormally

a

condition

NOTE:

service

fuel

injector

pressure

In

case

checked

center.

~INJECTOR

is

weak,

the

problem

the

valve

clearance,

compression

to

comes

high

that

might

of

and

Poor

to

the

seal

the

up,

the

reading

be

accompanied

severe

vibrations

overlw.uled

fuel

quality,

injection

is

still rings, rings

indicates

pump

low,

and

are

by

contaminants

HOLE

is

either

adjust

as

apply a small

repeat

faulty.

heavy

by

high

and

detonation

an

authorized

will

result

valve-

needed,

the

test.

carbon

pressure

fuel

and

in

injector

or

piston-

and

amount

If

accumulation,

noise,

injection

loss

test

of

the

and

have

of

positive

faults.

oil

noise.

the

NOTE:

be

performed

provided

ENGINE

WESTERBEKE

by a competent

to

assist

the

mechanic.

ADJUSTMENTS

recommends

engine

that

the

following

mechanic.

The

information

engine

adjustments

below

is

TESTING

NOTE:

The

THE

fuel

injector

FUEL

INJECTOR

must

be

serviced

in a clean

room

environment.

Removing

1. Disconnect the high pressure fuel line from the injector, then loosen the line at its attachment to the injection pump and move

bending the line.

2. Remove the fuel return line in its entirety from the top the injector. Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line

to

3.

Remove the fuel injector holder bracket mounting nuts, then remove the holder bracket.

4. Remove the fuel injector.

NOTE:

lifting

debris

will like, wrench

The injector seats in the cylinder head on a copper sealing washer. replaced with a new washer when the injector

5. Remove the gaskets.

6. Remove the

the

Fuel

Injector

it

out

of

the way

the injector.

Clean

the

area

around

the

it

out

of

the

cylinder

from

falling

not

lift

out

easily

worlc

the

injector

to

free

it,

and

This washer should be removed with

O-rings.

down

into

and

side-ta-side

then

head

is

held

lift

the

it

of

the injector. Avoid

base

of

the

to

help

prevent injector in

by

with

hole.

carbon

the

aid

out.

injector

prior

any

rust

if

the

injector build-up of a socket

the

injector and

is

reinstalled.

or

of

the

to

Checking

1. Set the nozzle tester in a clean place where there is no dust or

2. Mount the nozzle and the nozzle holder nozzle tester.

Use new fuel that has an approximate temperature

3. 68°F (20°C).

4. Bleed the air in the nozzle line by pumping the nozzle tester handle several times.

5. Slowly lower the nozzle tester handle and check the reading on the pressure gauge when the injection starts.

A

The

dBfl/J/y

it

enters

FUEL INJECTOR

The

Injection

dirt.

Injection starting pressure:

2900 Ib/in2 (200 - 203 kglcm2)

2850 -

CAUTION:

spray

into

the

Keep

nozzle

velocity

tllB

fingBIS

bloodstream,

Starting

hands

Is

and

away

such

hands,

It

may

Pressure

on

from

the

that

It

may

destroying

CBIISB

blood

the

nozzle

psnettate

tissue.

pOisoning.

of

spray.

If

Fuel

The

fuel

Injector

PRESSURE

Components

injector consists

NOZZLE

HOLOER

ADJUSTING

SPRING--I.

VALVE

PRESSURE

SHIMS

~

CONE--!

PIECE-e

of

the following parts:

~@

INJECTION

6.

If

the injection starting pressure is not within the specified range, adjust it appropriate thickness.

If

the thickness the injection pressure increases approximately 145lblin (10.1 kglcm

ADJUSTING

2

).

SHIM

by

replacing the shim with one

of

a shim is increased 0.004 in (0.1 mm),

PRESSURE

TEST

"

FUEL

INJECTOR

ADJUSTING

SHIM

of

a more

2

FUEL

INJECTOR

COMPONENTS

Engines & Generators

36

ENGINE

ADJUSTMENTS

Tightness

Apply a pressure leaks wash

from

and

of

the

recheck

CHECKING

the

Valve

of

2600

injection

the

injector

THE

NOTE:

be provided

Seat

Iblin2 (182

nozzle

holes.

nozzle

TIGHTNESS

WESTERBEKE

peiformed

to

kglcm2)

If

fuel

or

replace

OF

THE

VALVE

by a competent

assist

the

mechanic.

and

check

leaks,

disassemble,

it

SEAT

recommends

engine

if

fuel

that

the

following

mechanic.

Checking

1.

Check for damage and

2.

Check for damage body Then the

engine

adjustments

The

information

the

check for damage

upright release the needle valve and check that it drops into

valve seat under

below

Nozzle

Body

to

the valve seat of

to

the nozzle

and

insert four-fifths

its

is

and

Needle

to

other parts.

body.

own weight.

of

the needle valve.

Reassembly

Be

sure

to

do

the

following

1. Tighten the nozzle body onto the nozzle holder

specified torque.

torque:

Nozzle

29 - 36

when

ft-Ib

(4.0 - 5.0 kg-m)

reassembling

Valve

the

needle valve

Hold

the

the-fuel

nozzle

injector:

to

the

Inspecting

1. Mount the nozzle

2. Bleed the air in

tester handle several times.

3. Keep

tester just below the injection starting pressure while pumping the handle of the nozzle tester possible so that a pulsating whistling sound Check the

nozzle

Normal Pattern: all

five

Faulty Pattern:

injected substandard, or

replace

the

Spray

Pattern.

and

nozzle holder

the

nozzle line

the

reading

(see illustration).

NORMAl PAmAN PAmAN PAmRN

injection

fuel

is disassemble,

it.

on

the

pressure gauge of

atorni~tion

FUELIIUECTOR

The

nozzle

The

substandard.

of the fuel injected

FAUlTY FAUlTY

SPRAY

fuel

is

sprayed

holes.

number

of

fuel

If

the

wash

and

on

by

pumping

PAnERNS

uniformly

sprays

condition

recheck

the

as

and

of

the

the quickly

from

and

fineness

the

injection

nozzle

the

nozzle

is

heard.

the

finely

injected

tester.

as

from

of

the

fuel

nozzle

2.

After assembling starting pressure

Injector Installation

The

fuel

removal

1.

Use

2.

Replace

3. Tighten

Bracket mounting nuts torque:

is

and

injector

installation

sequence.

new

the

6 - 9

Make

gaskets - do not reuse

the

copper sealing washer

the

fuel

injector holder bracket mounting

specified torque.

ft-Ib

(0.8 -1.2

the

fuel

the

sure

TIGHTENING

NomE

THE

injector, check the injection

spray pattern.

sequence

kg-m)

to

include

is

the

THE

BODY

NomE

ONTO

HOLDER

reverse

following:

old gaskets.

for

each injector.

of

the

nuts

to

Engines & Generators

37

NOTE:

ments

be

below

is

ENGINE

WESfERBEKE

performed

provided

to

by

assist

ADJUSTMENTS

recommends

a

competent

the

that

engine

mechanic.

the

following

mechanic.

engine

The

infonnation

adjust-

DRIVE

The not the out turely. the belt

variations.

Checking

1.

BELT

ADJUSTMENT

drive

belt

must

be

properly provide a1temator. A drive

belt A

A

drive

proper

alternator

belt

of

alignment

Excessive

slipping,

WARNING:

belt's

To

check the belt tension, press the belt at the approximate midpoint alternator pulley and the flywheel pulley with a force of 221bs (10 kg!)

-

112"

slack

resulting

tension

Belt

(10 -

and/or

drive

belt

or

in

Never

while

Tension

Gust

(98

12

rnm)

tensioned. A loose

charging

that

cause

belt

tension

the

presence

high

attempt

the

above the bellhousing) between

N). The belt deflection should be 3/8"

deep.

is

too

tight

the

alternator

can

of

operating

to

engine

and

will

also oil

on

temperatures

check

Is

drive eventually pull

the

to

wear

out

cause

rapid

the

belt

can

and

or

adjust

in

operation.

ALTERNATOR

PUUEY

belt

will

damage

alternator

prema-

wear

of

cause

rpm

the

GOOD

3. Pivot the alternator on the base mounting bolt or right

4.

Tighten the base mounting bolt

bolt securely. Run

5. recheck the belt tension.

as

required,

the engine for about 5 minutes, then shut

to

loosen or tighten.

BAD

and

the adjusting strap

to

the

down

left

and

BELLHOUSING

Adjusting

1.

To strap bolt and

2.

With cracks and frayed edges.

it. groove, replace

Belt

Tension

adjust the belt tension, loosen the alternator adjusting

the

base mounting bolt.

the belt loose, inspect the belt for damage,

If

the

belt

is

damaged, replace

If

it is nearly worn out and deeply sunk

it.

flYWHEEL

.

PULLEY

FLYWHEEL

wear,

in

the

pulley

Engines & Generators

38

The

following

upon

certain

problems,

1.

Engine

troubleshooting

problem

and

the

recommendations

will

not

chart

indicators,

start

provides

the

probable

ENGINE

information

causes

to

overcome

of

them.

TROUBLESHOOTING

based

these

Problem

Fuel

supply

failure

(check

by

cranking

and

listening

characteristic

the

fuel

Poor

for

squirting

injector).

compression

engine

the

in

Probable

If

squirting

1.

No

fuel

2.

Vent

3.

Fuel

filter

4.

Faulty

5.

Faulty

6.

Fuel

7.

Broken

If

squirting

1.

Starting

2.

Gasoline

3.

Air

intake

1.

Automatic device

2.

Incorrect

3.

Valves

4.

Cylinder

5.

Piston

6.

Worn

7.

Rusty

8.

Valves

Cause

cannot

in

tank.

hole

in

tank

clogged.

injector

nozzle.

injection

line

cylinder

exhaust

pump.

blocked.

fuel

line

or

can

be

fuel

button

instead

blocked.

decompression

malfunction.

valve

clearance.

not

seating

head

loose.

rings

stuck

and

valve.

sticking.

be

heard:

cap

plugged.

leaking

heard:

not

pulled.

of

diesel

properly. in

grooves.

piston.

connection.

in

tank.

Remedy

1.

Fill

tank.

2.

Replace

cap.

3.

Replace

filter.

4.

Check/replace

5.

Check/repair/replace

6.

Check

7.

Replace

1.

Pull

button.

2.

Drain

gasoline,

3.

Check

1.

CheCk/replace

2.

Adjust

3.

CheCk/repair/replace

4.

lighten

5.

Check

6.

Overhaul

7.

Spray automatic

8.

Free

valves.

nozzle.

fuel

lines

and

fuellineltighten

flush

system

for

blockage.

automatic

valve

clearance.

cylinder

head

rings

and

clean

the

engine.

lubricating

oil

decompression

pump.

remove

blockage.

connections.

system,

fill

with

decompression

valves.

nuts.

the

piston.

into

the

cylinder,

device,

diesel.

activate

then

device.

the

start.

Difficult

2.

Engine

Faulty

Faulty exhaust

Poor

to

crank

the

engine

starts

but

fuel

supply

air

intake

and/or

system.

Compression

1.

2.

3.

fires

intermittently

2.

Lube

oil

too

thick. Bearings Piston

seized.

or

1.

Fuel

filter

clogged.

Water

in

fuel.

3.

Faulty

injector

nozzle.

4.

Faulty

injection

5.

Fuel

line

clogged.

6.

Fuel

lines

or

connections

1.

Restrictedlblocked

2.

Restrictedlblocked

See

Poor

Compression

Engine

will

not

soon

pump.

exhaust air

Start.

stops

leak.

system.

intake.

under

1.

Change

to

correct

viscosity.

2.

Overhaul

3.

Overhaul

1.

Replace

2.

Drain

3.

CheCk/replace

4.

CheCk/repair/replace

5.

Check

6.

Replace

1.

Check/clean

2.

Check/clean

the

engine.

the

engine.

filter.

fuel;

fill

with

nozzle.

the

fuel

lines

fuellineltighten

exhaust air

intake

clean

fuel.

pump.

and

remove connections.

system.

the

blockage.

(continued)

Engines &

39

Generators

3.

Engine

lacks

power

and/or

ENGINE

makes

black

TROUBLESHOOTING

smoke

Problem

Operating

Faulty

Engine

4.

Faulty

Engine

conditions

fuel

supply

condition

running

overheats

Probable

1.

Engine

2.

Power ambient been

3.

Clogged

1.

Gasket too

many

2.

Fuel

filter

3.

Faulty

4.

Faulty

1.

Excessive cylinder

2.

Faulty

3.

Worn

4.

Worn

1.

Engine

2.

Faulty

3.

Faulty

4.

Clogged

5.

Lube

6.

Faulty

Cause

overloaded.

reduction

considered.

under

injection

piston piston bearings.

ove~oaded.

raw

thermostat.

oil

injector

due

to

temperature

air

filter.

gaskets

clogged.

carbon

head.

water

raw

level

injector

are

nozzle. pump.

on

rings.

and

cylinder.

pump

water

intake

too

high.

nozzle.

has

missing

installed.

piston

altitude

impeller.

and/or

not

or

and

strainer.

Remedy

1.

Reduce

the

load.

3.

Clean/replace.

1.

Correct

the

number

2.

Replace

filter.

3.

Check/replace

4.

Check/repair/replace

1.

Decarbonize.

2.

Check/replace

3.

Overhaul

4.

Overhaul

1.

Reduce

2.

Replace

3.

Check/replace

4.

Clean

5.

Drain

6.

Check/replace

engine.

load.

impeller.

the

strainer.

to

proper

nozzle.

piston

thermostat.

level.

nozzle.

of

gaskets.

pump

ring

set.

Knocking

Engine

is

hunting

Engine

stops

suddenly

1.

Injector

2.

Fuel

3.

Broken

4.

Worn

5.

Worn

6.

Loose

1.

Engine

2.

Air

3.

Governor

4.

Fuel

1.

Fuel

2.

Vent

3.

Vapor

4.

Clogged

5.

Fuel

6.

Seized

7.

Seized

needle

timing

too

piston piston. bearings.

flywheel.

is

overheating.

in

fuel

lines. sticking

filter

clogged.

tank

is

hole

in

lock

injector.

line

is

broken. piston. crankshaft.

sticking.

far

ring.

empty.

fuel

tank

(fuel

is

advanced.

or

defective.

cap

is

plugged.

too

hot).

1.

Replace

2.

Adjust

3.

Replace

4.

Replace

4.

Replace

6.

Tighten

1.

See

2.

Check

3.

4.

1.

2.

3.

4.

5.

6.

7.

nozzle.

timing.

piston piston bearings.

flywheel

Engine

fuel

Free

the

governor

Replace

filter.

Fill

tank. Replace Cool Replace Replace. Replace Repair/replace

tank

the

nozzle. piston

fuel.

ring

set.

and

liner.

nut.

Overheats,

system

for

or

replace.

cap.

and

liner.

crankshaft

above.

leaking

and

connections.

bearings.

(continued)

Engines & Generators

40

ENGINE

TROUBLESHOOTING

Problem

Blue

White

Oil

in

5.

Low

smoke

exhaust

Oil

Pressure

oil

pressure

discharge

Probable

1.

Breather

2.

Oil

seal

3.

Worn

4.

Worn

1.

Fuel

timing

2.

Injector

3.

Low

engine

1.

Rings

2.

Low

compression -bad

1.

Incorrect

2.

Faulty

3.

Incorrect

Cause

valve

is

clogged.

at

intake

valve

is

valves/valve

piston/cylinder.

nozzle

not

oil

pressure

oil

guides.

is

too

late.

is

worn

operating

seated.

viscocity.

relief

filter.

temperature.

valve.

defective.

out.

valve.

Remedy

1.

Replace

breather.

2.

Replace

oil

seal.

3.

Replace

valves

and

4.

Replace

piston

and

1.

Adjust

timing.

2.

Replace

3.

Clean

1.

Initial

2.

Check/repair/replace

1.

2.

3.

nozzle.

thermostat. 50

Change

oil Replace Install

pressure

correct

hours

to

correct

oil

of

filter.

guides. cylinder.

operation

valves.

viscocity.

relief

valve.

required

to

seat

rings.

Engines & Generators

41

WESTERBEKE'S HURTH maintenance is

Model

included

7A-l

HBW

and

troubleshooting

in

the

following

40

INSTALLATION

NOTE:

linkLlge,

When

installing

ing

is

not

impeded

by

unsuitably

ing

radius

or

other

shift

control

cable

above

the

cable

the

WESfERBEKE

Shaft

Couplings

WESTERBEKE transmission

mounted, installation since bearing, not

exceeded. from sional

to

observe

Even pling

caused the

distance

gland

and

in

order

of a

the

propeller

provided

However,

additional

vibration.

the

manufacturers

with

the

engine

or DRNESAVER*

by

hull

distortions,

between

is

less

than

by

restricted

positioned

restrictions.

connections,

bracket

Parts

recommends a flexible the

propeller

to

compensate

special

thrust

the

value

loads.

When

solidly

the

about

and

llA-l

diesel

transmission.

infonnation

instructions.

the

transmission.

movability

guide

In

order

use

the

mounted

on

the

list.

shaft

if

the

for

angular

propeller

will

the

Special

using a universal

will

transmission

32

thrust

be

absorbed

specified

output

care

instructions.

mounted,

reduce

especially

in.

(812

under shaft should

stress

in

mm).

HURTH

engines

each

Installation,

for

this

make

certain

of

the

cable

sheaves,

two

bearing

the

wooden

output

too

to

mount a support

threaded

gear

housing.

connection

engine

is

flexibly

deflections.

is

not

by

the

transmission

SPECIFICATIONS

should

be

protected

be

taken

joint

shaft,

use

of a

flexible

in

the

gearbox

boats

flange

HBW

use

a

operation,

transmission

that

shift-

or

rod

small

a

bend-

for

holes

located

Refer

to

between

to

and

The

required,

prevent

make

certain

bearings

or

where

the

cou-

stem

TRANSMISSION

The

control

cable,

or

rod,

the

is

tor-

actuating

tion

of

the

neutral

The

shifting

ing

lever should the

inner

A

greater

is

recommended. clutch premature This

ment

NOTE:

season.

lever

the

shift

position

travel,

between

be

at

least

pivot

amount

engagement

wear,

would

be

at

all.

Check

when

lever

on

of as

measured

the

neutral

35

mm

point

of

shift

However,

might

excessive

indicated

for

proper

the

should

in

the

control

actuating

position

for

the

lever

if

the

be

impeded

heat

by

slow

actuating

be

arranged

neutral

position. console lever.

at

the

pivot

and

outer

pivot

travel

is

in

lever

travel

which,

generation

clutch

engagement

lever

at a right

The

should

points

end

positions A and

point

and

no

way

detrimental

is

shorter,

in

tum,

and

clutch

travel

at

angle

neutral

coincide

of

the

actuat-

30

proper

would

plate

or

no

least

each

to posiwith

mm

and

mean

failure.

engage-

_

B,

for

Shift

Control

The

transmission

loosening

any

Make

ing cover

A

the

actuating

the

position

lever

certain

cover

should

required

be

Caution:

actuating

lever

that

position A and

in

any

way

be

mid.

and

Actuating

is

suitable

retaining

the

plate:

0.02

The

lever

screw, for actuating

the

in.

(0.5

position

is

travel

Forward

tampered

Lever

for

single

lever

remote

the

actuating

the

shift

control

lever

minimum

mm),

(see

of

factory-adjusted

from

Neutral

position

with,

the

lever

(cable

does

not

distance

illustration).

the

mechanism position

B.

«this

transmission

control.

can

be

or

rod

linkage).

contact

the

between

lever

behind

to

ensure

N

to

Reverse

mechanism

warranty

Upon

moved

actuat-

and

equal

is

will

to

0.02

in.

(0.5

MINIMUM

ACTUATING

LEVER

COVER

mm)~~

DISTANCE

*DRIVESA

VER

is

a

product

o/Globe

Marine.

Rocldand

MA.

Engines & Generators

42

HURTH

HBW

TRANSMISSION

INITIAL

All engine is

Fill

111).

stick. screw checked, hexhead inspection

OPERATION

HBW

maine

at

the

drained

before

the

gearbox

The

fluid

To

check

it

in.

Screw

and

of

the

of

transmissions

factory

prior

shipment.

with

Automatic

level

should

the

fluid

the

tighten.

dipstick.

the

coupling,

DIPSTICK

to

be

level,

dipstick

Do

not

Check

oil

are

test-run

delivery.

Transmission

up

to

the

just

insert

into

the

forget

the

for

leaks

cooler

and

CHECKING FLUID

For

index

the

case

sealing

and hoses,

on a test safety

stand

reasons

fluid mark

on

dipstick,

after

the

ring

make a visual

and

TRANSMISSION OPERATING

I

FLUID

LEVEL

f!l[h

FLUID

DRAI~Ql.

I

FLUID

Change tion,

Removing

Push a suction bottom the of then transmission the

Drain

NOTE:

plug washer.

CHANGE

the

fluid

then

every

the

of

the

transmission

the

transmission

reinstall

engine,

shut

plug

torque:

When

sealing

A

WARNING:

engine

is

running.

hole.

This

for

300

Fluid

pump

housing

drain.

and

the

plug

and

properly

down

changing

washer.

could

the

first

operating

hose

down

and

suck Remove allow

with

its

dispose

and

recheck

20 -2S

the

fluid,

The

drain

Never

pullout

Hot

fluid will

cause

sever

time

hours

through

out

the

sealing

Mb

plug

after

about

or

at

winterizing.

the

fluid.

drain

plug

fluid

to

drain

washer.

of

the

used

the

fluid

(27.7 -34.6

take

care

will

leak

the

dipstick

splash

bums.

25

hours

dipstick

If

space

from

into a container,

Wipe

fluid.

level.

Nm)

not

to

lose

without

while

from

with

the

fluid

(DEXTRON

the

dip-

do

not

fluid

level

under

the

shift

cables.

of

opera-

hole

to

the

allows,

use

the

bottom

down

the

After

running

the

drain

this

sealing

the

dipstick

is

LOCKING

Locking

required: of

travel

corresponding

WHEN

Rotation

being

tion

tery),

DAILY

o

o o

o

NOTE:

from

idle

For Transmission and

Operating

A

too transmission

Normal

in

the temperature time.

Make provide

THE

PROPELLER

of

the

propeller

use

the

gear

for

this

purpose.

to

the

UNDER

of

sailed,

of

the

will

the

being

engine

have

SAIL

propeller

towed,

with

no

detrimental

OPERATION

Check

the

transmission Visually Start

warm Shift

check

the

engine

the

fluid.

into

gear.

Too

Iowan

the

transmission

speed

should

be

additional

TRANSMISSION

information

section:

Temperature

WARNING:

high,

stop

the

fluid.

operating

range

certain

good

temperature

of

1220 F

of

266° F (130

there

ventilation

shaft

shift

direction

OR

without a load,

the

gear

in

neutral,

idle

speed

gear

increased.

SHAFT

TROUBI.£SHOOTING.

if

the

engine

(50

is

enough

SPECIFICATIONS

TRANSMISSION

General

Gear

Ratio

(optional)

Lubricating

Transmission

Capacity Propeller

Direction

Fluid

Sump

Shaft of

Rotation

by

an

additional

lever

position

Never

put

the

of

travel

BEING

or

anchored

propeller

fluid shift

and

refer

transmission

0

C)

0

and

HURTH

case operated

2.05:1

A

0.37

Right

stopped

effects

level.

linkage

allowing a few

will

produce a chattering

damper

to

the

COUPliNGS,

immediately

of

the

to

2120 F

C)

may

space

around

cooling.

HBW

hardened

multiple

TF-

type

A

qts

(0.35

hand-standard

brake

opposite

gear

shift

of

the

boat.

TOWED

such

as

in a river,

(for

on

the

transmission.

and

transmission.

minutes

plate.

In

following

MAINTENANCE,

fluid

and

transmission

(100°

C). A

be

only

reached

the

transmission

40

Standard

helical

gears,

disc

clutch.

or

DEXTRON

liters)

transmission

is

not

your

direction

in

the

position

when

the

boat

as

well

as

opera-

charging

such

text

at

cases

in

the

idle

noise

this

to

the

temperature

check

the

fluid

should maximum for a short

to

Transmission,

with

a

servo-

-

/I

or

/1/

is

bat-

is

be

Engines & Generators

43

MAINTENANCE

Transmission clean, change

Periodically Lubricate

Lay-up/Winterize

Storage

o

Clean

heat

o

Fill internal more).

o

Loosen flange boat lubricant.

o

Inspect for

and

NOTE:

(twelve

prevent

putting

For

additional

HURTH MARINE GEAR ZF Industries Marine 3131 Fort Lauderdale, FL 33312 Tel.: Fax.: (954)581-4077

maintenance

check

the

fluid

inspect

the

cable

requires

up

the

resistant

the

transmission

corrosion

attaching

and

propeller

from

the

gear

corrosion

bending

If

the months internal

the

engine

information

US

SW

42nd Street

(954)581-4040

fluid

level

every

300

the

transmission

connections.

special

care.

transmission

paint).

with

(extended

hardware

shaft

water.

Separate

shift

cable,

of

the

end

of

the

cable

transmission

or

more),

corrosion.

back

Headquarters

is

minimal.

as

part

of

operating

Follow and

touch

Dextron

storage

from

coupling

the

linkage,

fittings,

rods.

is

to

it

sJwuld

Reduce

into

service.

contact:

HURTH

Keep

your

regular

hOUTS. for

leaks

these

procedures.

up

unpainted

III

ATF

only,

the

transmission

flange

flanges

and

attachments.

cracks

or

Lubricate

be

stored

be

topped

the

fluid

the

exterior

routine,

and

corrosion.

areas

fluid

to

twelve

months

output

before

removing

and

spray

cuts

in

the

all

moving

for a long

off

with

level

before

HBW

housing

and

(use

prevent

or

the

with

Look

conduit,

parts.

time

fluid

to

TRANSMISSION

Engines & Generators

44

CONTROL

The

majority lems mission

If

you

the

engine

have a helper

-

from

and

back

the

transmission. loose cable for

binding.

with

control

itself.

experience

down.

neutral

to

neutral -while

at

the

transmission

for

kinks

CABLES

of

move

HURTH

transmission

cables

rather

operating

First

check

the

cockpit

to

full

forward,

If

the

remote

and

or

excessively

difficulties

than

problems

the

transmission

shift

back

you

observe

is

stiff

try

again.

tight

bends,

HBW

arise

as a result

from

problems

with

the

lever

through

to

neutral,

the

actuating

to

operate,

If

it

is

and

TRANSMISSION

of

prob-

with

the

trans-

transmission,

fluid

the

into

break

still

stiff,

check

level,

full

lever

the

any

shut

then

range

reverse,

on

cable

check

linkage

the

TROUBLESHOOTING

A

new

cable needed. of make

If

helper peller fessional see have a folding

pitch"

NOTE:

While

gear

using

sure

the

transmission

put

shaft;

if

you

position.

If

immediately marine

transmission

and

perhaps a new

the

cable

the

actuating

there's

no

passes

it

in

forward

if

the

shaft

attention.

still

have a propeller

or

feathering

you

suspect

contact

is

loose,

lever

binding

these

and

isn't

If

it

does

a major

your

WESTERBEKE

facility.

linkage

shift

on

inside

tests,

reverse

turning,

tum

but

on

the

propeller,

problem

mechanism

the

side

the

case.

crank

while

the

transmission

there's

end

that

in

may

transmission

of

the

transmission

the

engine

you

observe

no

thrust,

of

the

shaft

it

isn't

stuck

your

transmission,

dealer

or

an

be

in

and

have

the

pro-

needs

pro-

check

to

or,

if

you

in

the

authorized

out

to

a

"no

Problem

Transmission be

shifted.

into

gear.

Transmission gear, the

boat.

Delay

or

engages

increase

Chattering noise, speed.

Fails

but

fails

of

gear

only

in

speed.

transmission

mainly

gears

shifts to

engagement

at

cannot

to

move

into

propel

after

an

low

engine

1.

Actuating

2.

Shifting Cable

Actuating

3. plate.

Output

1.

Propeller

2. coupling

Output

3. both

1.

Actuating N

to

2.

Actuating

3.

Actuating The

1.

vibrations

a

"chattering"

Probable

lever

cable

radius

lever

coupling

shaft is

tuming.

coupling

turning.

lever

A.

Refer

lever lever

engine

in

Cause

is

loose.

is

broken,

is

too

severe.

is

binding

is

not

turning.

is

not

turning.

and

propeller

travel N to B not

to

diagram.

travel

is

binding

or

propeller

the

drive

unit

noise

in

the

bent

or

unattached.

against

cover

Output

shaft

equal

insufficient.

against

cover

generates

torsional

which

produces

transmission.

are

to

plate.

1.

Tighten

damping

2.

Check

the

Detach

3.

1.

2.

3.

1.

2.

3.

1.

2.

the

hand.

Clearance

Transmission The

coupling

on

the

propeller

pins

and

Inspect

the

folding

propeller

may

be

in

Adjust

cover

Refer

to

Check

actuating

Check

clearance,

Mount a flexible

between higher

stiffness

Inspect

the

transmission.

bolt

cable,

reattach

shift

cable

should

needs

bolts

shaft.

coupling

bolts

propeller;

may

"no

pitch"

plate

actuating

lever

adjust

coupling

the

transmission

factor

damper

Replace

Remedy

on

actuating

or

replace.

and

operate

be

0.02

professional

are

sheared

or

Tighten

or

as

necessary.

it

may

be

position.

until

cable

plate

missing

jammed. A variable

the

lever

text

and

length.

if

necessary.

with

another

coupling

might

be

sufficient.

between

if

necessary.

lever.

the

actuating

in.

(0.5

mm).

attention.

the

coupling

replace

or

is

exact

mid

diagram.

Refer

stiffness

and

the

engine

lever

is

slipping

set

screws,

damaged.

pitch

propeller

position.

to

lever

diagram.

factor

driveshaft.

and

the

by

keys, A

A

Transmission

louder.

Boat max.

Oil

leakage.

tails

to

speed.

noise

attain

becomes

specified

1.

Damage wear ment

Beginning

2. mission

without of

1.

Operating

Corrosion

1.

Damaged

2.

Misalignment

starting

or

between

transmission,

on

fatigue,

possibly

engine

damage

due

to

torsional

fluid,

overload,

or

temperature

at

radial

sealing

of

output

flexible

coupling

due

and

the

of

bearings

vibrations,

wrong

excessive

is

high.

sealing

ring

ring.

flanges.

Engines & Generators

due

to

misalign-

drive

shaft.

in

trans-

running

alignment

engine

output.

and

shaft.

45

to

Check

1.

2.

1.

2.

alignment, persists, mission

Transmission

Wrong

type

Check

fluid

Transmission Check

alignment.

inspect

and

the

needs

of

level.

needs

inspect

the

damper

engine.

professional

fluid;

use

professional

Must

flexible

plate

Replace

ATF

type

be

within

coupling.

between

if

necessary.

attention.

A

or

DEXTRON

attention.

0.003

in.

If

noise

the

(0.08

trans-

/I

mm).

or

III.

GENERAL

Many

owners

rely

on including or lay-up

The lay-up if

These lay-up of

If

local assistance.

PROPELLER

The opened the cradle. propeller

put by hauled

dry

LUBRICATING

With Fill

to an

for

FUEL

Top

as algae tives tor fuel

separator

leaks.

engines

for

long

periods

preparation

procedures

and

others

procedures

and

your

you

have

servicing

transmission

water

in

the

these

out

for a considerable

the

SPECIFICATIONS

API

proper

A

Caution:

oil

in combustion chemicals intemal

which

recommissioning,

do

the

procedures.

also

help

engine.

any

questions

dealer;

up

and

the

or

moved

The

flexibility

shaft

or

water.

strains.

of

the

engine

sump

with

specification

oil

pressure

the

sump

deposits

which

parts.

SYSTEM

off

your

fuel

BlOB

OR

AND

and

condition

used

are

compatible

used

in

the

system.

ftlter/water

sediment

Clean

up

and

of

themselves.

should

SHAFT

and

bolts

from

coupling

In

some

This

water

SYSTEM

warm,

the

Do

over

tanks

STA-BIL

separator,

bowl.

any

their

boatyards

generators,

inactivity.

follow

will

or

afford

familiarize

regarding

he

will

be

COUPLING

propeller

of

does

period

correct

of

and

not

can

the

spilled

half

removed

land

to

the

boat

or

both,

cases,

not

apply

when

not

of

drain

all

amount

section

CF

or

CG-4.

make

leave

the

lay-up

combine

reduce

with

No.2

should

fuel.

Care

with

the

Change

if

the

Reinstall

fuel.

LAY-UP

to

prepare

for

lay-up

during

Others

prefer

allow

you

may

use

your

engine

you

with

the

lay-up

procedures,

more

than

willing

couplings

when

the

boat

water,

and

during

often

puts a severe

while

the

shaft

has

to

small

in

use,

unless

time.

the

engine

oil

of

oil

of

this

manual).

Run

the

sure

there

are

the

engine's

period.

to

produce

the

life

of

diesel

fuel.

be

added

should

be

primary the fuel

ftlter

system

and

make

fuel

element

AND

their

craft,

the

off

to

accomplish

to

perfonn

them

as a check

protection

maintenance

should

boat

actually

boats

from

for

engine

Engine

your

at

taken

has

during

to

provide

always

is

hauled

storage

strain

is

taken

been

that

they

have

the

your

engine

Use

and

no

leaks.

old

engine

oil

harmful

engine's

Fuel

additives

this

time that

filter/water

in

your

one,

and

certain

there

RECOMMISSIONING

Change

the

fuel

ftlter

elements

season

your

needs

call

out

in

on

out

bent

are

been

oil

sump.

an

oil

check

and

to

control

the

primary

clean

own

list

your

be

of

the

or

(refer

with

such

addisepara-

the

are

no

SYSTEM)

and left created needed. movement the

Long-Term

For a long-tenn described

Disconnect pump. mixture short Set decompression engine to

RAW

Remove raw

Allow replacement, impeller cover

AIR

Remove

soaked

opening.

recommissioning,

may remove can

CYLINDER

To Then Rotate fogging

silencer.

If

WESTERBEKE access cylinder walls. start replacements

and

bleed

the

fuel

allow

it

to

run

for

5-10

in

the

fuel

in

the

Operate

of

engine.

above,

Fill a suitable

of

9/10

suction

the

speed

approximately

the

idle

position.

WATER

the

water

in

it

to (into

and

gasket.

system.

fuel

the

Lay-Up

the

pipe

control

impeller

the

drain

if

the

Check

system

during

the

engine

treated

fuel

Procedure

lay-up,

follow

then

do

the

fuel

supply

container

diesel

fuel

and

between

lever

to

device

to

its

20

times.

COOLING

from

cylinder

completely.

needed,

pump)

Drain

head

and a cover

until the

line

the

your

INTAKE & THROUGH-HULL

the

air

intake

silencer

in

lubricating

Do

need

the

cloth

be

blocked

protect

the

spray

fogging

the

engine

oil

into

you

anticipate a long

to

the

to

prevent

After

or

the

hand

not

shove

and

assistance

prior

in

the

AND

VALVES

cylinder

oil

two

the

air

recommends

cylinder,

the

squirting

crank

for

the

oil,

in

the

an

attempt

of a

to

start-up.

same

and

into

revolutions

intake

lay-up

then

piston

the

oil,

to

distribute

injector

on

the

engine

system,

as

needed.

minutes

for

any

this

5-10

through

to

make

leaks

servicing,

minutes. the

injection

(over

the

fuel

system

following:

from

the

fuel with a 0.132 1110

anti-corrosion

container

full

neutral

load,

position,

Put

the

and

set

speed

CIRCUIT

raw

water

coolant

chamber

Examine

recommissioning,

water

gasket.

lift

muffler.

the

EXHAUST

and

place a clean

the

air

intake

opening

cloth

out

of

sight

is

made

to

servicing

manner.

valves,

the

again.

squirting

rings move

and

dealer).

The

through-hull

remove

cylinder

using

Replace

period

(12

removing

light

from

the

return

head the

months

the

sticking

piston

oil.

line

(see

FUEL

Start

sure

there

that

may

correcting

This

equipment

12

months)

lay-up

tank

at

U.S.

gallon

oil.

the

fuel

the

automatic

then

hand-crank

control

pump

and

to

drain

impeller.

Do

not

replace

but

cloth,

to

(if

it

is

start

the

Make a note

the

air

intake

air

intake

hand

crank.

the

air

or

fuel

injector

lubricating

to

by a quick

Make

sure

sealing

the

engine

is

no

have

been

them

will

allow

procedures

the

fuel

lift

(0.5

Connect

lift

pump.

lever

back

allow

the

out.

Acquire

the

replace

the

lightly

block

the

not

visible

engine,

exhaust

silencer.

opening.

Spray

intake

more)

for

oil

into

the

cylinder

electric

you

have

washers.

air

as

of

litre)

a

the

a

at

you

to

port

the

Engines & Generators

46

LAY-UP

AND

RECOMMISSIONING

STARTER

Lubrication Make to

remove

electrical

MOTOR

and

sure

the

connections

cleaning

battery

starter.

connections Take removed

BATTERIES

If

batteries sure them remain environmental warmer,

A

highly-explosive arcing

smoke serviced.

ity

are

to

be

they

are

fully

charged,

from

freezing.

full

charged,

conditions,

more

compatible

WARNING:

or

a

lighted

or

allow

Shut

to

prevent

electrical

left

If

there

or

that

Lead

gas,

cigarette,

an

open

off

all

TRANSMISSION

Check

or

change

the

fluid

off

grime

and

grease

and

the

coupling

Check For

additional

HBW

SPARE

Lay-up WESTERBEKE belt kit

and

during

PARTS.

and

the

that

the

transmission

information,

TRANSMISSION

PARTS

time

provides a good

engine

or

coolant

hoses

order

items

the

lay-up,

such

output

need

not

of

the

starter

care

in

from

on

board

and

will

is

any

they

will

remove

environment

acid

batteries

which

flame

electrical

arCing

in

the

touch

up

flange

vent

see

Lay-uplWinterize

section.

opportunity

to

see

if

replacement.

on

hand,

as

filters.

drive

pinion

are

shut

off

properly

during

doubt

the

starter.

the

remain

be

subjected

batteries

replacing

that

the

emit

can

be

ignited

cigar,

or

pipe.

near

the

equipment

during

servicing.

transmission

any

unpainted

with

an

anti-corrosion

is

open.

to

external

or

items

Check

replace

those

See

SUGGESTED

is

before

lay-up

period,

way,

batteries

to

and

store

hydrogen,

by

Do

battery

in

as

required.

areas.

in

the

inspect

such your

items

advisable. attempting

any

make

to

prevent

will

not

severe

them

a

electrical

not

being

the

vicin-

Wipe

Protect

coating.

HURTH

your

as

the

drive

basic

spares

used

SPARE

in

STORAGE

Thoroughly engine

in

a

clean

dry

place,

RECOMMISSIONING

The

recommissioning

a

sonallay-up

described section However, counteracted

1.

Remove

and

2.

Remove discard

Install during lay-up (or a replacement, if required). Install raw

3.

Reinstall lay-up, terminals are clean Check

4.

Start

FOR PROCEDURE sections of

generally

in

the

regarding

some

before

the

through-hull exhaust

the

raw

water

pump

the

and

to

make sure that

A

CAUTION:

and

eye

protection

acid

batteries

which

can cigarette, open

flame

all

electrical

the

engine

INITIAL

the

outside

of

the

engine,

then

protected

of

follows

PREPARATIONS

preparation

of

the

lay-up

starting

oil-soaked cloths

raw

water pump cover

old gasket.

water

cover

batteries that

reconnect the battery cables,

emit

be

ignited

cigar

near

equipment

arcing

in

START-UP

against

the

your

WESTERBEKE

the

same

procedures

FOR

INITIAL

for

starting

procedures

the

engine.

from

port.

pump

impeller that

with a new

were

removed during

and

that

the

connections

the

batteries

Wear

rubber

gloves, a rubber

when

servicing

hydrogen, a highly

by

electrical

or

pipe.

Do

not

the

battery

during

accordance

being

in

the

vicinity

servicing.

with

and

STARTING/STOPPING

this

manual.

weather.

and will

the

and

cover

smoke

the

store

the

engine

after a sea-

as

those

START-UP

normal

starts.

need

to

be

air intake

gasket

was

gasket.

making

are

fully

opening

and

removed

the

sure

are

tight.

charged.

apron

batteries.

Lead

explosive

arcing

or

a

lighted

or

allow

serviced.

PREPARATIONS

to

prevent

Shut

the

gas,

an

off

KEYSWITCH

Lubricate

mechanism

MAINTENANCE

the

keyswitch

functions

with

freely

WCKEZE to

with

no

binding.

ensure

that

the

switch

Engines & Generators

47

7

A·1 & 11

A·1

TORQUE

SPECIFICATIONS

Cylinder Connecting Cylinder

Main

Fuel

Delivery

High

Injector

Governor

Aywheel

Gear

Push

Crank

Oil

Sump

Banjo

Rocker

Oil

head

bearing

lift

pump

injection

valve pressure pressure

clamp

on

end

cover

rod

guide

handle

pump

plate bolt bolt

bracket

filter

rod

on on

Component

cover

plate

pump

holder-injection

fuelline-injection fuel

line-fuel

crankshaft

guide

fuel

lift

tank

injector

pump

SPANNER

SIZE

(mm)

13 13 13 13 13 13 14 17 17 10 14 36

6 4

10

5

cross-slotted

17

12 13

-

MOOEl7A-1

TIGHTENING

MIN.

TORQUE

30 30

8 30 30 30

34

18 25

8 55

216

34

8

8 16

9 25

8 30

-

(Nm)

MAX.

33

12 33 33

33

39 22 30 12 60

226

38 10 12 20 11 35 10 33

-

SPANNER

SIZE

(mm)

17 14 13 13 13 13 14 17

17

13 14 46

6 4

10

5

cross-slotted

17 12 17

-

MODEL

11A-1

TIGHTENING

MIN.

TORQUE

52 52 56

8 30 30 30

34

18 25 20 55

390

34

8

8 16

9 25

8 52

Hand-tighten

-

(Nm)

MAX.

56

12

33

33 33

39

22 30 23 60

410

38 10 12 20 11 35 10 56

Engines & Generators

48

BOLT

HEAD

MARKINGS

1.

Use

the

2.

These

torques

3.

Reduce

torque

values

are

torques

based

by

30%

listed

on

or

STANDARD

below

when

specific

clean,

dry

threads.

more,

when

threading

torque

Reduce

capscrews

HARDWARE

Metric

bolt

class

strongest

values

torque

into

are

not

by

10% aluminum.

numbers

available.

when

engine

identify

oil

is

used.

bolts

by

their

strength

with

10.9

the

STANDARD

C8psrew

Body

1/4-20

-28

5/16

-18

-24

3/8

-16

-24

7116-14

-20

1!2

-13

-20

9/16

-12

-18

5t8

-11

-18

314

-10

-16

7/8-

-14

1 - 8

-14

SIze

9

(Inches) -(TIIread)

BOLT & NUT

SAE

Glade

5

TDIqIII

FHb

(Nm)

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(41)

49(66) 55

(75)

75

(102)

85

(115)

110

(149)

120(163) 150

(203)

170

(231)

270

(366)

295(400)

395

(536)

435

(590)

590(800) 660(895)

TORQUE

SPECIFICATIONS

SAE

Glade

Torque

Ft-lb(Nm)

10

(14)

19(26)

34(46)

55

(75)

85

(115)

120

(163)

167

(226)

280

(380)

440

(591)

660

(895)

6-7

SAEGrada8

Torque

R-Lb(Nm)

12

(16)

14

(19)

24

(33)

27

(31)

44

(60).

49(66) 70

(95)

78

(106)

105

(142)

120

(163)

155

(210)

·170

(231)

210

(285)

240

(325)

375

(508)

42!"(569)

605

(820)

675

(915)

910

(1234)

990

(1342)

METRIC

Bon

Wrench

Ola.

M3

M4

M5

M8

M9

Ml0

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33

M36

BOLT & NUT

Size

5.5mm 7mm 8mm

10mm 13mm 16mm

18mm 21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

Grada4.6

A-Lb(Nm)

0.3

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

TORQUE

Grade

A-Lb(Nm)

0.5

33

85

118 166 225

288 417 568

774 992

SPECIFICATIONS

4.B

(0.1)

1

(1.5)

2(3)

4

(5.5)

10

(13)

18

(25)

(45)

55

(75)

(115)

(160) (225) (305)

(390) (565) (770)

(1050) (1345)

Grade

B.B -9.8

FI-Lb(Nm)

1

(1.3)

2

(3)

4.5

7.5

(10)

18

(25)

37

(50)

63(85)

103

(140)

159

(215)

225

(305)

321

(435)

435

(590)

553

(750)

811

(1100)

1103

(1495)

1500

(2035)

1925

(2610)

(6)

Grade

10.9

R-Lb(Nm)

1.5

(2)

3(4.5)

6.5

(9)

11

(15) 35(26) 55

(75)

'fl

(130)

151

(205)

232

(315)

321

(435)

457

(620)

620

(840)

789

(1070)

1154

(1565)

1571

(2130)

2139

(2900)

2744

(3720)

GASmSJSEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper ing

assembly.

Specialized ing copper

gasket

non-hardening

cylinder-head

12

They

are

water,

oil

or

of

OIL

or

red

sealant

of

the

gaskets

SILICONE

ADHESIVE

sealers

properties.

gaskets

and

it's

HIGH

effective

fuel.

LlaUID

TEFLON

should

oil

pan

gasket

that

seal

around

grease.

SPRAYS

such

as

HYLOMAR

as

it

TACK

in

just

about

can

be

used

with

water

are

useful

HYLOMAR

is

resists

fuel,

equivalent

be

high

for

particlarly

SEALANTS

are

excellent

all

any

jOint

in

contact

with

used

on

rubber

gaskets

on

oil

adapter

hoses

and

temp

RED

SILICONE

(coolant)

work

oil

holding

well

and

passages,

gaskets

in

applications

effective

water.

coat

in

position

on

&

LUBRICANTS

Use

LlaUID

passages.

TEFLON

Do

nat

BOIis & FASTENERS/ASSEMBUES

Ughtly

oil

plugs

oil

dur-

HIGH When Anti-seize

threaded LOCTITE

LITHIUM

ing

Heavily

use

the

sealer.

both

requir-

Engines & Generators

head

that

penetrate

TACK.

assembling

compounds components offers

based

boxes.

oil

all

clean

engine

sliding

49

for

use

bolts

and

the

levels

grease

and

all!

sealing

tape

flywheel,

yet of

pipe

sealants!

other

fasteners

water

jacket

coat

and

thread

allows

locking

according

is

waterproof,

reCiprocating

plugs

should

the

locking

them

to

ideal

components

and

fillings

as

you be

sealed

bolt

threads

adhesives

came

apart

to

the

for

water

that

assemble

with

LOCTITE

such

as

when

job.

pump

when

connect

coolant

them.

Bolts

PERMATEX

blue.

LOCTITE

protect

necessary.

bearings

and

assembling.

and

#2

or

stuff-

Always

METRIC

CONVERSIONS

INCHES TO MILUMETERS MILUMETERS TO INCHES

Inches

1 2 50.80 20 508.00 3 4 5

10

mm

25.40 15

76.20

101.60

127.00 35

254.00 40 1016.00

MILLIMETERS

Inches

25 635.00

30 762.00

= 1

CENTIMETER,

mm

381.00

889.00

100

CENTIMETERS

mm

1 0.0394 15 0.5906 2 3 0.1181 25 0.9843 4 5

10

= 1

Inches

METER = 39.37

INCHES TO METERS METERS TO INCHES

Inches

1 0.0254 7 0.1778 2 3 4 5 0.1270 6

Meters

0.0508 8 0.2032 0.2 7.874 0.8 31.496

0.0762 9 0.2286

0.1016 10 0.2540 0.4 15.748 1.0 39.370

0.1524

TO

CONVERT

METERS

Inches

11 12

TO

CENTIMETERS,

Meters

0.2794 0.5 19.685

0.3048 0.6 23.622 1.2 47.244 MOVE

Meters

0.1

0.3

DECIMAL

Inches

POINT

YARDS TO METERS METERS TO YARDS

Yards

1 0.91440 6 5.48640 1 1.09361 2 1.82880 7 3 2.74320 8 4 5

Meters

3.65760 9 8.22960 4 4.37445 9 9.84252

4.57200

MOVE

DECIMAL

Yards

10

POINT

FOR

Meters

6.40080

7.31520

9.14400

HIGHER

Meters

2 2.18723 7 7.65529

5

VALUES -e.g.

3

3.28084 8

5.46807

6,000

METERS = 6,561.68

mm

0.0787

0.1575

0.1969 35 1.3780

0.3937 40 1.5748

3.937 0.7 27.559

11.811 0.9 35.433

TWO

PLACES

Yards

20

30 1.1811

INCHES

Meters

1.1

TO

THE

Meters

6

10

(3.3

FEET)

RIGHT

10.93614

YARDS

Inches

0.7874

Inches

43.307

Yards

6.56168

8.74891

Ib

1 0.454

2

3 1.361 8 3.629 4 1.814 9 5 2.268

Gallons

1 3.79 10 2 7.57 3 11.36 4 5 18.93

kg

0.907

GALLONS

Uters

15.14

Ib

6 2.722 7 3.175

10 4.536

TO LITERS LITERS TO GALLONS

Gallons

20 30 40 50

PINTS TO UTERS

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Pints

1 0.47 2 3 1.42 8 4 5 2.37 10

32

I I

I

0 5

Uters

0.95 7 3.31 2 4.23 7 14.79

1.89 9

40

I

Pints

50 60

I

I I

I

6

70

I

10 15 20 25

kg

4.082

Uters

37.86

75.71

113.57

151.42

189.28

Uters

2.84 1

3.79

4.26

4.73

kg

1 2 3 4 5

Uters

1 2 5

10

20 5.28 180

Uters

3 6.34 8 4 8.45 9 5

TEMPERATURE

75 85

I

I I I I

I I

30

11.023

Gallons

UTERS

Pints

10.57

95 105

I

35

40

Ib

2.205

4.409 7 15.432

6.614

8.818

0.26

0.53 90

1.32

2.64

kg

6

8

9

10

Liters

60

120 31.32 150

Ib

13.228

17.637

19.842

22.046

Gallons

15.66

23.77

39.62

47.54

TO PINTS

Pints

12.68

16.91

19.02

21.13

OF

I

2.11

140

Liters

6

10

175 212

I

I I I

100

60

80

°C

Engines & Generators

50

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x 1.609 =

Kilometers

METRIC

(mm)

(m)

x

3.281

(km)

x

CONVERSION

x

.0394

=

Feet

.0621

=

Miles

DATA

Inches

VOLUME

Cubic

Inches

(in3) Imperial Imperial Imperial Imperial Imperial

Fluid US US US

Pints Quarts Gallons Quarts

Gallons

Ounces

Pints

(US Quarts Gallons

x

(US

(IMP

29.573

pt)

qt)

gal)

MASS-WEIGHT

Ounces Pounds

(oz)

(I

b)

x

28.35

x

.454

PRESSURE

Pounds Inches Inches Inches

Inches Inches

Per

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

Sq

In

x

16.387

pt)

qt)

(IMP

qt)

(IMP

x

.473

x

.946

x

=

Kilograms

(psi)

(Hg)

(Hg) (H20) (H20)

(H20)

=

x

.568

x

1.137

gal)

x

1.201

gal)

x

=

Milliliters

=

Liters(L)

=

Liters

3.785

Grams

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

Cubic

Centim~ters

= liters

(L)

= liters

4.546

= liters

=

US

Quarts

1.201

=

US

Gallons

x

.034

x

2.113

(L)

x

1.057

=

Liters

(L)

x

(g)

x

.035

=

(kg)

x

2.205

=

Kilopascals

=

psi

x

2.036

=

Kilopascals

=

Inches

=

psi

x

27.684

=

Kilopascals

x 1.76 =

(L)

x.88

(L)

x

(US

=

Ounces

=

Pints

=

.264

=

Ounces

=

Pounds

(kPa)

=

(kPa)

of

Mercury

=

(kPa)

x

.061

IMP

=

IMP

.22

qt)

(US

Quarts

Gallons

x

Hg

H20

x

=in

pt

=

IMP

x

.833

gal)

.145

x

.2961

x

13.783

4.026

qt

3

x

=

gal

=

.833

psi

=

H20

IMP

=

Hg =

H20

qt

IMP

gal

TORQUE

Pounds-Force Pounds-Force

Inches

Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles

Kilometers

Per

(Hp)

Hour

IMP

Per

liter

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(DC) = (OF

(in-Ib)

(ft-Ib)

x

1.609

x

.745

=

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(OF) = (DC

-

x

.113

1.356

=

Kilometers

Kilowatts

x

.354

=

x

2.352

x

.425

x

2.352

X

1.8) + 32

32) x .56

=

Newton

=

Meters

(Kw)

x

1.34

Kilometers

IMP

MPG

Kilometers

=

US

MPG

Meters

Per

Hour

Per

=

MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-Ib

=

ft-Ib

=

MPH

Engines & Generators

51

SUGGESTED

Carry

only

SPARE

Genuine

WESTERBEKE

PARTS

Spare

KITS

Parts

SPARE

WESTERBEKE each Kit Kit

Kit

PARTS

offers

packaged "A" "B"

"A"

Drive Belt Raw Fuel Filter Fuel Lift Oil Fuel Hardware

Air Intake Filter

"B"

Drive Belt Raw Raw Fuel Filter Fuel Oil

Fuel Thermostat Complete Gasket

Fuel Injector

Air Intake Filter

in a rugged includes is

for

the

more

includes:

Water

Pump

Filter (Model lOA-I only)

Includes:

Water

Pump

Water

Pump

Lift Pump Screens (2) and Gasket

Filter

(Model

Hardware

Kit

KITS

two

Spare

Parts

Kits,

hinged

toolbox.

basic

spares.

extensive

Screens (2) and Gasket

Kit

off-shore

Impeller and Gasket

(to

fix

Impeller and Gasket

Repair Kit

lOA-I only)

(to

fix

Kit

cruising.

a leak)

Engines & Generators

52

Engines

& Generators

1045-

.5C-4JD1

Westerbeke 7A-1, 11A-1 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual