Westerbeke W35B, W 42B, W38B Operator's Manual

OPERATORS

MANUAL

358

MARINE

Three,

388

DIESEL

Four,

ENGINES

428

Four

J'W

PUBLICATION

REVISION.

MARCH

NO.

3

2018

037435

'WESTERBEKE

j

WESTERBEKE

j

MYLES

WEB

SITE:

NMM4

----

~--

CORPORATION•

STANDISH

INDUSTRIAL

WWW.WESTERBEKE.COM

Member National Marine Manufacturers Association

150

JOHN

PARK•

HANCOCK

TAUNTON

MA

ROAD

02780

A

WARNING

Exhaust colorless unconsciousness exposure

•Dizziness

gasses

gas.

carbon

can

include:

•Nausea

·•Headache

•

Weakness

IF

YOU

BET

OUT

seek

medical

until it

and

DR

ANYONE

INTO

luls

been

,.t

THE

attention.

contain

carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•Muscular

•Vomiting

•Inability

of

to

ANY

an

carbon

in

Twitching

OF

l•EBIATELY.

down

the

unit

and

repaired.

A

WARN/NB

WESTERBEKE

bulkhead

WESTERBEKE

CARBON

living/s/eepiilg

Tiiey

obtainable

DECAL

and

near

your

also

MONOXIDE

are

inexpensive

at

your

quarters

odorless

and

Temples

Think

niEsE

N

symptoms

and

is

should

engine

recommends

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

provided

be

fixed

or

DETECTORS

of youi

and

easily

local

marine

persist,

by

to

a

generator.

installing

in

the

vessel. store.

·

...

I .

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

other

diesel

and

some

to

the

cancer,

reproductive

65

and

of

State

WARNING

gasoline

its

birth

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

caused

by

failure precautions. take

the

personnel,

The

following

the

American

PREVENT

A

while

power.

II

Do enclosures and covers in place.

II

Shut off electrical power before accessing electrical equipment.

II

Use insulated mats whenever working on electrical equipment.

II

Make sure your clothing and skin (particularly shoes) when handling electrical equipment.

II

Remove wristwatch and all jewelry when working on electrical equipment.

PREVENT

A

exhaust

Know

necessary

and

your

safety

Boat

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not operate this machinery without electrical

BURNS -HOT

WARNING:

system

hat!

Ill Monitor engine antifreeze coolant level at the plastic

coolant recovery tank and periodically at the filler cap location on the water jacketed exhaust manifold, but only when the engine

A

WARNING:

1111

In

case of

before touching the engine or checking the coolant.

an

engine overheat, allow the engine

carefully.

to

follow

fundamental

when

dangerous

precautions

to

protect

Most

conditions

machinery. instructions

and

Yacht

are

Council

in

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

or

Is

present

when

connected

at

these

are

ENGINE

Oa

not

touch

hat

engine

components. A running

is

COLD.

Steam

can

cause

injury

accUlents rules

are

and

exist

yourself,

your

compliance

standards.

connections

to

shore

connections!

dry,

not damp

parts

or

engine

gets

or

death!

to

and

with

cool

.

very

PREVENT

A

Ii

Prevent flash sparks to occur near the carburetor, fuel line, pump, or other potential sources vapors. Use a suitable container to catch all removing the fuel line, carburetor, or fuel

11\l

Do Backfire can cause severe injury or death.

Ill

Do not smoke or permit the fuel system. Keep the compartment and the engine/generator clean and free chances of

I'

Be aware - diesel fuel will burn.

PREVENT

A

injury

l!J

Follow re-fueling safety instructions. hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine.

!kl

All fuel

when ventilated area away from spark-producing equipment and out

Ell

Do not

E?J

Shut off the the fuel system. spill. sources servicing. the fuel system.

iJ

Do not alter or modify the

fJ Be sure all fuel supplies

11~

Be certain fuel line fittings are adequately tightened free of leaks.

a Make sure a

properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the for all applications encountered in this environment.

BURNS -FIRE

WARNING:

not operate with the air cleaner/silencer

fires.

fire.

Fire

can

cause

injury

Do not smoke or permit

of

flames

or sparks to occur near of

debris to minimize the

Wipe up

all

spilled fuel and engine

or

spilled

death!

fuel

filters.

BURNS -EXPLOSION

WARNING:

or

death!

handling and storing fuels. Store fuel in a well-

fill

DO

of

Explosions

vapors

are

highly

of

the reach of children.

the fuel tank(s) while the engine

fuel

service

Take

NOT allow

fire

near

the

Ensure proper ventilation exists when servicing

fire

extinguisher is installed nearby and is

from

fuel

explosive.

valve care in catching any

smoking; open

fuel

system

fuel

have

Use

at

the engine

or engine

system.

a positive shutoff

NFPA

vapors

Keep

the vessel's

extreme

is when

any

fuel

flames,

when

are appropriate

flames

fuel

removed.

can

runni.Qg.

or

filter,

fuel

or

fuel

when

oil.

cause

care

servicing

that might

or other

valve.

and

Engines

& Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death/

11

Turn

unit's

engine.

• Make certain all personnel are clear of the engine before starting.

•

Make certain re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

• Do not smoke or

being serviced. Lead acid batteries emit hydrogen, a highly explosive arcing or equipment in the vicinity during servicing.

• Never connect the negative(-) battery cable

positive ( Do not test the battery condition by shorting the terminals together. Ventilate accumulation of explosive gases. disturb is being charged.

•

Avoid burns or sparks

wristwatch, rings, and

battery.

the

• Always tum the battery charger off before disconnecting

the battery connections and reconnect it last when servicing

BATTERY

A

WARNING:

severe

• When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber protection. Batteries contain sulfuric acid which is destructive. it off at once into the eyes inadvertently when removing electrolyte caps.

STARTING

OFF

the

battery

Accidental

DC

breaker

selector

all

covers, guards, and hatches are

starting

on the control

switch

to

OFF

can

cause

panel

before

injury

or tum

servicing

EXPLOSION

Battery

by

lit tobacco products. Shut

+) connection

Sparks could ignite battery gases or fuel

any

compartment containing batteries

the battery charger connections while the battery

contacting

explosion

allow

an open

gas,

which can be ignited

to

terminal

the

terminals with tools, etc., to prevent

that could cause

any

..

Remove the negative lead first

can

cause

flame

near the battery

by

o~

all

prevent electrical arcmg

to

of

the

starter solenoi?.

To

avoid

sparks,

!111

explosion.

other Jewelry before handling

the

battery.

injury

elec~cal

ele~lrical

the

to

Remo~e

ACID

Injury

SUifuric

or

death!

If

it comes in contact

with

water.

acid

Acid

in

batteries

with

may

can

apron,

and eye

your skin, wash

splash on the skin or

cause

the

the.

vapors.

prevent

do

not

TOXIC

El

Iii

EXHAUST

A

WARNING:

Ensure that the exhaust system is adequate discharged from the engine. Check the exhaust system regularly for leaks water-injected

Be sure the unit and its surroundings are well ventilated. Run blowers when running the

GASES

Carbon

and

elbow

is

monoxide

make

securely attached.

(CO}

is a deadly

sure the exhaust manifold/

geµerator set or engine.

to

gas!

expel

gases

a Do not run the generator set or engine unless the boat is

equipped with a functioning marine carbon monoxide detector that complies with ABYC A-24. Consult your boat builder or dealer for installation of approved detectors.

Iii For additional information, refer

(educational information on Carbon Monoxide).

A

WARNING:

odorless nausea

ID

11

l!I Although diesel engine exhaust

AVOID

A

or

lill

gas.

or

Do

not use copper tubing in diesel exhaust systems.

Diesel

fumes systems. copper tubing resulting in exhaust/water leakage.

Do not install exhaust outlet where exhaust can be through portholes, vents, or air conditioners. exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet flow

of exhaust.

exhaust gas

is present in diesel exhaust symptoms or signs of carbon monoxide inhalation or poisoning

Vomiting Dizziness Headache Nausea Weakness and sleepiness

MOVING

WARNING:

death!

Do not service the engine while it is running. situation make operating adjustments, use extreme care touching moving parts and hot exhaust system components.

Carbon

Inhalation

monoxide

produces

death!

can rapidly destroy copper tubing in exhaust

Exhaust sulfur causes rapid deterioration of

Avoid

overloading the craft.

fumes

from gasoline engines, carbon monoxide

are:

Inability Throbbing Muscular twitching

PARTS

Rotating

arises

in which it is absolutely necessary

parts

to

ABYC

(CO}

Is

Ru-like

aµd

close or restrict

gases

are not

fumes.

Some of

to

think coherently

in

temples

can

cause

TH-22

an

Invisible

symptoms,

drawn

If

the engine

as

toxic

the

Injury

If

a

to

avoid

the

as

Engines & Generators

ii

Ill

Do

not

wear

equipment;

rings,

.

moving

111

Make Keep places

111

Do

not

.

the

engine

11

Stay when be

caught

HAZARDOUS

A

WARNING:

avoid

necklaces

parts

sure

all attaching

protective

at

all

times.

check

is

clear

of the

the

engine

in

these

NOISE

loss!

11

Never

operate

111

Do

not

run

an

removed.

A

WARNING:

mentally

OPERATORS

·Many in

your

notes

carefully, procedures.

01

of

the

Operators

to

highlight

maintain

physically

MANUAL

preceding

SAFETY

loose clothing or jewelry

wearing

or

loose jackets,

bracelets

that

..

hardware

shields

and

guards

fluid

levels

or

the

operating.

drive

shaft

and

is

running;

rotating

High

noise

an

engine without its·muffler

engine

Oo

not

incapacitated by

safety

Manual

critical infonnation. Read your

your

equipment,

hair and clothing

parts.

l~vels

with

the air intake (silencer)

work

an

tips

and

along

with

when

shirts,

could

be

is

properly

in

their respective

drive

belt's

the

transmission

can

cause

machinery

fatigue!

warnings are'fepeated

other cautions

and

follow

servicing

sleeves,

caught

tightened.

tension

can

hearing

installed.

when

you

and

manual

all safety

INSTRUCTIONS

in

while

coupling

easily

are

ABYC,

.

~NSTAR.LING

Read for safety tions

ABYC

"Safety Order

ABYC

613 Annapolis, (

410)

·

www.abycinc.~rg

NFPA "Fire Protection Standard for Motor Craft"

Order NFPA

1 Batterymarch Park

P.O.

Quincy,

USCG (United States Coast "CFR Code of Federal Regulations

Order

U.S.

Washington,

NF

the

following

codes

when

(American

Standari:ls

From:

Third

Dtreet,

MD

990-4460

(National Fire Protection Association)

From:

Box

9101

MA

33

AND

From:

Government

PA

AND

USCG

PUBLICATIONS

MARINE

and

installing your UNIVERSAL

21403

02269-9101

CFR46"

D.C.

ENGINES

ABYC,

Boat

for Small Craft" ·

Suite

Printing Office

20404

NFPA

standards.

and

Yacht

10

Guard)

Follow

AND

and

USCG their

Council)

FOR

GENERATORS

publications

recommenda-

engine

ENGINE

Preparations ough (ABYC) sources

Sections

All Regulations

AND

examination

standar.ds.

including

of

H-32 H-33 P-1

Installatiion of Exhaust Systems and

P-4

Marine E-11 TA

Batteries

installations

GENERATOR

to

install

an

engine should begin

of

the

American

These standards are a combination of

the

USCG

the

ABYC

standards of particular interest

Ventilation Diesel

Auxilliary

AC & DC

(FCR).

for boats using diesel

Fuel

Systems

Engines

Inboard

must

Engines

Electrical Systems on Boats

and

Battery Chargers

comply

INSTALLATIONS

with a thor-

Boat

and

Yacht

and

the

NFPA.

fuel

for

Propulsion

and

Transmissions

with

the

Federal Code of

Council's

are:

Engines & Generators

iii

When

installing WESTERBEKE engines

to

the

attention be paid

following

INSTALLATION

and

generators it

information:

is

important that strict

CODES

Strict federal regulations,

when

AND

REGULATIONS

installing engines

ABYC

guidelines,

and

generators in a marine environment.

and

safety codes must be complied with

SIPHON·BREAK

For installations where the exhaust manifold/water injected exhaust elbow or

will

be below the vessel's waterline, provisions must be made

raw

break in the minimum of

the

exhaust manifold

raw

water

If

you

have

to

the vessel's waterline under

water supply hose

20" above

damage

any

doubt about

to

injection

the

vessel's waterline.

engine

to

the

exhaust

Failure

port is at

and

the

position of

the

or

below

possible

vessel's various operating conditions, install a

flooding

the

water-injected exhaust elbow relative

siphon-break.

NOTE:

A siphon-break operation. engine

EXHAUST

The Exhaust Hose and and system under

Failure

damage.

SYSTEM

exhaust system's hose

is turns without the need of additional turns.

In this regard, a single length of corrugated exhaust hose can be

MUST

any

sea conditions

requires

to

properly maintain a siphon-break

Consult

recommended. The use of

be

designed

periodic inspection and cleaning

the

siphon-break manufacturer for proper

MUST

be certified

fitting

to

and

prevent

at

the

any

angle of vessels

for

this

and

entry

type

of water into

elbow.

This hose must be looped a

to

the

load

of

can

marine

of hose allows for extreme bends

clamps

heel.

to

install a siphon-

use

a siphon-break

waterline

the

boat.

result

use.

Corrugated Marine

to

accomplish these bends

the

will

to

ensure

in

catastrophic

maintenance.

exhaust system

is

close

when

result

proper

used.

to

in

AVAILABLE

YOUR

DEALER

SIPHON~BR'EAK

wop·

The

FROM

WESTERBEKE

WITH

STAINLESS

A

detailed engines to

and

download

Marine

Installation generators, from

our

Manual

is

supplied

website

at

Engines & Generators

covering

with

www.westerbeke.com.

iv

each

gasoline

unit. A pdf

and

diesel,

is

available

TABLE

OF

CONTENTS

Introduction

Warranty Procedures ...................................... 2

Serial Number Locations ............................... 3

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

Parts

Identification

Transmission

Propeller Recommendations .........................

Fuel,

Engine

Oil Pressure ................................................... 6

· Coolant Recovery Tank ................................. 6

Preparations Admiral Captain Starting/Stopping Engine The

Daily Warning Maintenance Cooling

Changing Coolant ................. ~ ...................... 16 Torquing Cylinder Head Bolts

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

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

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

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

Raw Water

Zinc Anode ..................................................

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

Fuel

System

Fuel/Water

Fuel Filters ................................................... 20

Fuel Lift Pumps ...........................................

Fuel Injectors ...............................................

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

Glow

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

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

Data

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

Oil

and

for

Control

Break-In

Operation

Lights,

Schedule

System

........................... : .......... ~ ...........

Pump .........................................

Coolant

Initial

Panel

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

Panel

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

Procedure

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

Alarms

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

Start-Up

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

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

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

and

Circuit

(Chart)

Breaker

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

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

Separator ................................... 20

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

2

.4

5

.5

6

7

8

9 Battery Care........................ . ...................... 30

1 o

11

12

....

13

14 Adjusting Idle Speed .............. ; ...................

16

17 18 18 18 18

19 19

20

20 21

21 21

Engine

Oil Remote

Torque Tachometer Water Starter DC

Wiring

Wiring Engine

HBW·ZF

HBW·ZF JS Borg

Metric Specifications

Lay-Up Suggested

Lubricating

Changing the

Pressure

Testing Oil Pressure .....................................

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

Oil

Filter

Specifications

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

Oil Filter ................................ 22

Oil ......................................... 22

(Optional)

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

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

Heater

Motor

Electrical

Alternator Troubleshooting ......................... 29

Schematic Diagram

Troubleshooting

Coolant Temperature/Oil Pressure Gauges .34

Belt Tension and Maintenance .................... 35

Valve Clearance Torquing Cylinder Head Bolts Valve Clearance

and

BW

Warner

Coolers ................................................... 46

Oil

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

System

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

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

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

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

(358) (388/428)

Transmissions Transmission

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

(Chart)

Transmissions

Transmission

Conversion/Hardware

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

W35B Three ................................................ 48

W38B Four .................................................. 50

W 42B

Four

.................................................. 52

and

Recommissioning

Spare

Parts

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

22

23 23

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

24 24

25

26

27

29

31 31

.32

.35

(358)

... : .....

.36

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

(388/428)

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

......

~

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

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

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

(Chart)

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

J ...... 36

..

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

.37

37 38

.41

42

44

.47

48

54

.56

·

Engines & Generators

1

This

WESTERBEKE WESTERBEKE's technology. dependable Thank

In

order important manual ual

carefully

out.

nearest

This

provided

WESTERBEKE

equipment, WESTERBEKE' S installation

We performance

you

for

to

get

that

is

designed

and

Should

your

WESTERBEKE

is

your

operators

and a technical

contact

WARRANTY

Your

WESTERBEKE

folder.

If,

after

form

you

have registering writing serial

Customer

your

with

model

number

Identification

Diesel

long

ye~

take

great

pride

of our engines

selecting the

you

WESTERBEKE.

full

use

and

operate

observe engine

dealer.

and

to

help

you

,illl

require

dealer

manual.

manual

If

you

your

WESTERBEKE dealer

PROCEDURES

Warranty

60

days

of submitting

not

received

warranty,

and

please

information,

commission

INTRODUCTION

Engine is a product of

of experience

in

the superior durability

benefit from your engine, it

main~n

do

this.

the

safety precautions

servicing, contact

for

assistance.

A parts catalog

is

available

are

planning

manual.

is

iftcluded in a separate

a customer identification

contact

including

date.

Card

and

it

Please

the

Warranty the

and

advanced

generators.

correctly.

read

is

also

from

to

install

for

factory

the

engine's

this

through-

your

Registry

i::rus

this

·

card

in

and

is

man-

PRODUCT

Product software, (technical brochures WESTERBEKE

WESTERBEKE

CONTENT OF SUCH RANTIES THERETO, COMPLETENESS THEREOF AND BE

UABLE

INCURRED

OF

THE

WESTERBEKE

span

and

product software. The proguct software provided

WESTERBEKE

other suppliers, must

sively

not

only representatives of WESTERBEKE or the supplier be

consulted

product software being consulted

NOTES,

As

this maintenance schedules, engine, CAUTIONS,

SOFTWARE

data,

and

catalogs), provided

are not within WESTERBEKE's

CANNOT BE RESPONSIBI.E

SOFTWARE,

OR

REPRESENTATIONS WITH RESPECT

INCLUDING

FOR

ANY

IN CONNECTION

FURNISHING

customers should

between

the

printings of WESTERBEKE product

unavoidable existence of earlier

products, whether

as

the

definitive authority

makes

good sense but

to

determine

CAUTIONS

manual takes

critical information

and

WARNINGS.

ACCURACY,

TYPE

OF

OR

USE

not

and

cannot

the

accuracy and

AND

WARNINGS

you

through

and

troubleshooting of your

will

parts lists,

from

sources other

MAKES

TIMEUNESS

WIU

IN

DAMAGE

WITH

OR

ARISING OUT

OF SUCH

keep

in

mind

WESTERBEKE

from

WESTERBEKE

be

relied

on

the

respective

is

imperative

by

the

customer.

the

operating

be highlighted

An

explanation

manuals,

FOR

NO

OR

SOFTWARE.

upon

that

currentness

by

than

control.

THE

WAR-

OR

EVENT

INJURY

the

time

software

with

exclu-

product.

appropriate

in

question

of

procedures,

marine

NOTES,

follows:

or

It

the

Customer

MR. MAIN

HOMETOWN,

Model

Expires

The meric ufacture date

consists acter D= and manufacture.

Identification

ENGINE

STREET

358

Three.

10/15/02

WESTERBEKE

number

of

your

code

is

placed

of a character

indicates

1990s

),

the

second

OWNER

USA

Serial

engine serial number

that

can

assist in determining

WESTERBEKE

at

the

end of the engine serial number

followed

the

decade

(A=1960s, B=l970s,

first

number

and

third

numbers

#

_____

engine. The manufacturer's

by

three

represents

represent

is

numbers.

the

year

0402

an

the

C=1980s,

in.

the

alphanu-

date of

The

the

decade,

month

man-

char-

of

and

NOTE:

An

operating procedure essential

A

CAUTION:

obsllmnl, your

engine.

A

WARNING:

lowed,

can

Procedures

can

result

which,

in

the

damage

ProcedufllS

in

personal

which,

injury

to

note.

if

not1strictly

or

destruction

if

not

properly

or

loss

of

fol·

life.

Engines & Generators

2

INTRODUCTION

SERIAL

The located water can just this below,

technical

~VE1llt*t=Tl:I)

•

UNDER&TMBING

The

since are same has

rods Therefore,

preventive important

nance lubricating ods

sediment, important factor

high

diesel

The

however,

carburetor

component -the

function

NUMBER

engine's

on

a nameplate that

jacketed exhaust

also

be found stamped into

above

the

information

as

this

information and/or ordering parts.

MODEL

diesel

engine closely resembles

the.mechanism is essentially

arranged

general type

the

same type of

and

lubricating

to

maintenance

factors

of

the

filter

specified,

etc.)

detergent

engines.

diesel

engine

in

and

of

both.

LOCATION

model

designation and serial number are

is

mounted

manifold.

manual

will

above a closed crankcase. The crankshaft

a great extent, a diesel engine requires

fuel,

its

shut-off

on

the

provide a quick reference

SPEC

THE

as

a gasoline engine,

valves,

system.

are

proper ventilation

lubricating

elements

and

frequent

in

the

fuel

is

the consistent use of the same brand of

diesel

lubrication oil designed

does

metl1od

ignition systems are replaced

fuel

injection pump - which performs

lever.

illustration of the

W04

DIESEL

camshaft, pistons, connecting

as

a gasoline engine. The most

and

must be replaced at the time peri-

checking for contaminants

system is also essential. Another

differ from

of handling and firing

on

the side of

The engine's serial number

the

fiat

block surface located

Take

the

time

name

when

MA"'"

ENGINE

the

cooling systems. Fuel

the

,

gasoline engine,

same. The

and

the

·

and

proper mainte-

specifiCally

gasoline engine,

by

the

to

enter

plate

shown

seeking

SER.NO.

~ylinders

is

diesel engine

the

(water,

of

fuel.

The

a single

0

the

same

and

for

the

ORDERING

Whenever replacement parts

engine

the silver and black nameplate located

must identify descriptiqn separately packaged parts because will fit or

not

made

SPARES

Certain WESTERBEKE will

'J

assist

the

SPARE

sories;

PARTS

model

number and serial number

provide

us

with

this

your engine.

and

furriished

to

the

AND

spares

you

PARTS

see WESTERBEKE's

In

part number for each part

Parts

same specifications

ACCESSORIES

will

be needed

engine.

in

preparing

page

are

needed,

information

addition, include a

List).

Insist

to

support

Your

local

an

inventory of

in

this

manual.

ACCESSORIES

always

as

on

so

we

upon

generic

as

original

and

WESTERBEKE

For

provide

they

appear

the

manifold.

may

properly

complete

needed

WESTERBEKE

parts

spare

engine

part

(see

are

frequently

equipment.

maintain

parts.

acces-

brochure.

the

your

dealer

the on You

See

1-W-IWESTERBEKE

I Engines &

Generators

3

PARTS

IDENTIFICATION

Connections

Secondary Fuel Filter

W

Lube

428

Air Intake Silencer

Oil

Dipstick

FOUR

Top Engine Oil Fill

Lube Oil Filter

MARINE

DIESEL

DC Charging

Alternator

ENGINE

Shut-of!

Lever

Lube Oil

Drain Hose-

,Throttle lever

RIGHT

Top

Engine Oil Fill

SIDE

Fresh Water Fill

LEFT

SIDE.

Fuel Lift

pump

W

388

Air Intake Silencer

Lube Oil Filter

FOUR

Top

Oil Fill

Sender

MARINE

DIESEL

DC Charging

Alternator

Shut-off

Lever

Lube Oil

Drain Hose

Fresh Water

Circulating Pump·

ENGINE

RIGHT

Top

Engine

Starter with Solenoid

SIDE

Oil Fill

Fresh Water Fill

LEFT

SIDE

90" Exhaust Elbow

Engines & Generators

4

Starter

with Solenoid

Fresh Water

Bleed

Air

Fresh Water Circulating Pump

PARTS

Unit Data Plate

IDENTIFICATION

20AmpDC Circuit Breaker

90'

Exhaust Elbow .

Heat Exchanger

LEFT

SIDE

Starter with Solenoid

W35BTHREE

MARINE

TRANSMISSION

(standard

JS

ALL

MODELS.

Transmission

DIESEL

DATA

ENGINE

General:

)

Standard Propeller

Gear Shaft

Fuel

Instrument Connections

Zinc Anode

Transmission

Dipstick

JS Transmission

Ratio:

Rotation:

20 Amp DC Circuit Breaker

Lift Pump

Lube Oil Dipstick Oil Pressure

Case-hardened gear.

Reversing

2.

47:

1.

Right

Hand.

helical

is

carried

gears

out

Sender

with

an

intermediate

by a servo

RIGHT

double

SIDE

reverse

disc

system.

DC

Charging

Alternator

Side Oil

Fill

Shut-off Lever

Lube

TransmiSsion

and

· .

Transmission

Propeller

Oil.

Grade.

Sump

Capacity:

Recommendations:

{;nginps

' 5

API

Spec.

CG-4,

CH4,

SAE

20W

or

SAE

Do

not

rnlx:9f8des

of

1 Quart ( 1 LitPr ).

428

FOUR

...

180.x

388THREE 358THREE

Propeller

at

full

&.

...

1611.x

...

16:0x10P.

should

allow

open

throttle

Generators

while

Cl-4,

30

exclusively.

oil

and

do

12P,

two

12P;

two two

the

engine

underway.

SJ,

not

use

blade

blade blade

to

reach

SL,

SM,

dr

multigrades

or

180

x10Pthree

or

t60ll1PPthree

or

160 x 8P,

its

full

better.

oils

three

rated

blade

blade. blade.

RPM ( 3600

+I -100)

DIESEL

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

DIESEL

USE A DIESEL

(No.

Care

Use only clean diesel in your particles which might pass through the filter can damage these and keep it clean. The best fuel can be rendered unsatisfactory by careless handling or improper storage facilities. engine's daily use

advisable:

Purchase a well-known brand of diesel fuel. The use of

additives is Kleen diesel fuel when an Ultra Low Sulfur diesel is being used. DO

Install and regularly service a good, visual-type fuel filter/water separator between the fuel tank and the engine. The such filters.A

ENGINE

Use

SAE for the engine model you have. The engine oil and filter must be changed after the initial Then follow the oil and filter change intervals the Westerbeke Corporation does not approve or disapprove of the break-in must.be performed using conventional oil. Oil

change intervals must be

SCHEDULE,

OIL

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

by

normal operation, the oil pressure may range from

25

at

FUEL

WITH

2-D

(SAE

J313)

Of

The

Fuel

fuel

injection pump is very critical; invisible dirt

finely

finished parts.

To

assure that the fuel going into the tank for your

is

to

combat BACTERIAL growth in the fuel tank

recommended such

+ cetane Boost

NOT

use

any additives containing ALCOHOL.

Raycor 500

10

MA

micron

CETANE

diesel

fuel

Supply

fuel!

clean and pure, the following practice

as

Bio-Bor and e such

to

help restore lubricity back into the

or 230 RMAM are good examples of

filter

RATING

according

The clearance of the components

It

is important

element

OF

#45

OR

to

ASTM

D975).

to

buy clean

as

Diesel

is

recommended.

OIL

a heavy duiy engine oil with an API classification and

as

specified

MAINTENANCE

use of synthetic oils.

in

the Specifications section of this manual

50 hours

SCHEDULE

If

synthetic oils are used, engine

as

in the MAINTENANCE

not extended because synthetic oils are

of

break-in operation.

as

specified in

in this manual.

PRESSURE

the

oil

pressure gauge on the instrument panel. During

psi (l.75 kg/cm

rated

rpm.

2

at idle upwards of 80 psi (5.6 kg/cm

)

HIGHER.

fuel,

is

used.

2

)

ENGINE

WESTERBEKE recommends a mixture of and 50% distilled chemicals that can corrode internal engine

The antifreeze performs double run at proper temperatures the engine cooling circuit from rust quality antifreeze that contains Supplemental

Additives (SCAs) that keep the antifreeze chemically

balanced, crucial The distilled water and antifreeze should be premixed

being poured into the cooling circuit.

PURCHASING

Select a brand of antifreeze specified for diesel Antifreeze specified for diesel engines contain a special additive cylinder walls. Prestone and Zerex brands that offer antifreeze specifically for engines. Select the pre-mix variety will always be added Change the antifreeze mixture according

MAJNTENANCE SCHEDULE in

COOLANT

water.

Distilled water

duty.

by

transferring heat

to

the coolant, and lubricates

and

corrosion. Look

to

long term protection.

is

It

allows

ANTIFREEZE

to

protect against cavitation erosion of

are

two

so

that

to

the cooling system

this

manual.

50%

free

surfaces.

and

protects

Cooling

nationally

the

when

to

the

antifreeze

from

the

engine

away

from the

for a good

engines.

the

engine's

use

in

correct

needed.

MAINTENANCE

Change the engine coolant every number of operating hours

protect and lubricate the engine have a limited

COOLANT

A coolant recovery tank kit engine. or generator. The purpose of allow for engine coolant expansion engine operation, without the loss of coolant introducing air into the cooling system. This kit

and must be installed before operating

NOTE:

located at or above can

particular installation makes this

RECOVERY

This

tank,

be

located below

with

the

its

the

short

level

as

the

TANK

is

supplied

run

of

the

level

of

five

years

regardless

chemical additives

life.

with

each

this

recovery

and

contraction

and

is

the

engine.

of

plastic

hose,

engine's the necessary.

engine's

manifold,

manifold

tank

during

without

provided

is

to

before

known

diesel

mixture

of

the

that

is

to

best

but

it

if

the

NOTE:

A newly started, cold engine can have

reading

an

readings engine and the load placed

TRANSMISSION

Refer type of

up

to

60 psi

(4.2

oil pressure reading as

fvill vary dependinJ upon the temperature

FLUID

to

the TRANSMISSJON SECTJON

fluid

and quantity for each transmission

2

kglcm

low

as 25 psi ( 1.8

on

the engine.

).

A warmed engine can have

an

oil pressure

2

kg!cm

).

These

of

the

of

this manual for

model.

lwlWESTERBEKB

f

Eng/"9S

&

6,

Generators

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

Before longed

0

Check at

0

Tum examine nants.

0

Check

NOTE:

transmission

O

Check and

( +)

the stud

0

Check and

NOTE:

refer

0

Visually parts,

the

0

Make engine. performance.

0

Make

0

Ensure

transmission.

0

Open strainer.

INSPECTION

starting

layoff,

the

battery

your

check

the

engine

high

mark

on

the

fuel

the

transmission

Refer

to

the

DC

battery

cable connections. Make certain

cable

negative(-)

(this

location

the

coolant

at

the

manifold.

If

the

engine

to

the

COO

examine

disconnected

threaded

certain there

An

ample

sure

the

propeller shaft

the

through-hull

Inspect

engine

for

the first

the

following items:

oil

level.

Add

oil

on

the

dipstick.

supply,

then

check

fuel

filter/water

the

electrical system. Inspect

is

connected

cable

is.ll:agged).

level

has

UNG SYSTEM section

the

wires,

connections

is

supply

mounting

the

raw

separator bowl

fluid

level.

page for

to

the starter solenoid

is

connected

in

both

the

not yet been filled

engine. Look

and

unattached hoses. Check

and

engine attachments.

proper ventilation

is

necessary

installation

is

securely attached

and

prime the

water

supply.

time

or after a

to

maintain

the

fuel supply

fuel,

to

the

plastic recovery

for

loose or missing

for

is

secure.

raw

the

for

contami-

oil and

wire

connections ·

the

positive

engine ground

with

coolant,

of

this

manual.

around

the

proper engine

to

water intake

the

pro-

level

and

tank

PLASTIC

~--~

~...,.

GLOW CONNECTION

RECOVERY

PLUG

TANK

Oil.FILL

CAP

DIPSTICK~

Engines &

~nerstors

7

ADMIRAL

CONTROL

PANEL

DESCRIPTION

This

manually-operated control panel

KEY

switch

and

RPM gauge with

which

meter in

1/10 ATURE Fahrenheit, an engine's

measures the engine's running time

hours.

The

panel

also includes a

gauge

which

indicates water temperature

OIL

PRESSURE gauge which measures the

oil

pressure

in

pounds per square inch, and a control circuit VOLTAGE gauge which measures the tem's

voltage. switch is

in

operation.

pushbuttons,

RPM

GAUGE:

TERS

REVOLUTIONS

PER

MINUTE

ENGINE

AND RECALIBRATED ACCURACY REAR

OFTHE

is

turned

REGIS-

OF CAN

FOR

FROM

PANEL.

one

THE

BE

THE

All

The

gauges

on

for

and

panel

are illuminated when the

remain illuminated while

also contains

PREHEAT

WATER GRADUATED ILLUMINATED TURNED TEMPERATURE

is

equipped with a

an

ELAPSED TIME

WATER

two

rubber-booted

and

one

for

START.

TEMPERATURE

ON.

IN

DEGREES

WHILE

THE

ENGINE'S

IS

170°

GAUGE:

THE

-190°

FAHRENHEIT

KEY

NORMAL

in

hours and

TEMPER-

in

degrees

DC

sys-

key

the

engine

THIS

GAUGE

AND

SWITCH

IS

OPERATING

F

(77° -88°C).

IS

When

the

engine

is

the

water

temperature

temperature reading

power

was

turned off. The

when

the

key

switch

will

once

again

register

electrical A

Admiral necting electrical the be running.

on engine's

separate

the

buzz.er

audible and

should

po"'.er

is

alarm

buzzer

Panel.

The

buzzer

harness.

in a location to

the

operator

The

buzzer

silence

oil

pressure

The

shut

down

with

gauge

will

continue

indicated

is

restored

installer

to

the

will

when

rises

Oil ATED ILLUMINATEDWl-ULE ON. PRESSURE

(2.1-4.2

by

the gauge

oil

pressure gauge

turned

off. The temperature

the

engine's true

to

the gauge.

with

harness

is

responsible

four-pin

installer

where

sound

PRESSllRE

THE

it

should

the

above

If\!

POUNgS

ENGINE'S

kg/cm').

is

will

it sound when engine has

15

RANGES

connection

also responsible

MUGE:

the key

temperature

is

supplied

be

dry

while

the

ignition

psi (1.1

THIS

PER

SQUARE

THE

NQl)fl.:'IAL

BElWEEN

switch

to

register

before

will

fall

with

for

electrically

on

the

for

and

where the

engine

key

started

and

2

kg/cm

).

GAUGE

IS

INCH

KEY

(PSI)

SWITCH

OPERATING

30 -60

turned

off,

the

last

electrical

to

z.ero

gauge

when

every

con-

engine's

installing

it

will

is

turned

the

GRAOU·

AND

IS

TURNED

OIL

psi

IS

HOURMETER: REGISTERS TIME, USED THE

SCHEDULE.

PREHEAT

THE POWER THE THIS DC BUTION.

START

STARTER'S

THIS

UNLESS AT

~

ELAPSED

AND

SHOULD

AS A GUIDE

MAINTENANCE

BUTION:

CONTACTS

TO

THE

PREHEAT

IS

TRANSMITTED

POWER

IS

BUTION:

SOLENOID

BUTION

THE

PREHEAT

THE

SAME

BE

FOR

WHEN

IN

THE

PREHEAT

GLOW

PLUGS.

SOLENOID ALSO

WILL TIME.

TO

TRANSMITIEO

WHEN

PRESSED,

WHICH

NOT

BUTION

DEPRESSED,

SOLENOID

THE

"I"

ALSO

THE

OPERATE

TERMINAL

RECEIVES

ELECTRIC

TO

THE

ENERGIZES

CRANKS

ELECTRICALLY

IS

PRESSED

IT

CLOSES

SENDING

POWER

FUEL

START

THE

ENGINE.

AND

·

ON AND

PUMP.

THE

HELD

'

'.---,,,r

,

AUTOMATIC COOLANT

SUPPLIED REACHES ALARM

OIL LOCATED THE FALL

ING SIGNAL.

ALARM

TEMPERATURE

WITH

210°

WHICH

PRESSURE

OFF

ENGINE'S

TO

10

- 5

THE

ALARM.

~

SYSTEM

THE

INSTRUMENT

F

(99"C),

WILL

EMIT

ALARM:

THE

ENGINE'S

OIL

PRESSURE.

psi

(0.7 -0.4

IN

THIS

ALARM:

AN

THIS

AN

PANEL

SWITCH

A

CONTINUOUS

OIL

PRESSURE

OIL

GALLERY.

SHOULD

kg/cm'),

EVENT.

THE

ALARM

IFTHE

WILL

SIGNAL.

ALARM

THIS

THE

SWITCH

ALARM

KEY

SWITCH: SWITCH ON

SUPPLIES

TO

THE PANEL SWITCH,

TERMINAL

CHARGING AND

TO BUZZER A

PULSING

DC

VOLTMETER:

INDICATES

.BATIERY

SHOULb

BUZZER

HAS

ENGINE'S

CLOSE

SOUNDING

SWITCH

ENGINE'S

OIL

WILL

EMIT A PULSATING

THE

KEY

WHEN

TURNED

DC

POWER

INSTRUMENT

CLUSTER,

MONITORS

CLOSE

PREHEAT

EXCITATION

OF

THE

DC

ALTERNATOR

THE

ALARM

ENERGIZING

MODE.

THE

AMOUNT

IS

BEING

CHARGED.

SHOW

13V

TO

BEEN

COOLANT

THE

IS

PRESSURE

SOUND·

IT

IN

THE

14V.

Engines & Generators

8

CAPTAIN

CONTROL

PANEL

DESCRIPTION

This manually-operated control panel

KEY switch, an RPM gauge, PREHEAT and START but-

tons,

an

lamps,

INSTRUMENT

one

for

ALTERNATOR

'JEST button and three indicator

OIL PRESSURE, and one for high ENGINE COOLANT

TEMPERATURE.

RPM

GAUGE:

MINUTE REAR

OF

REGISTERS

OF

THE

PER RECALIBRATED THE

REVOLUTIONS

THE'ENGINE

FOR

ACCURACY

PANEL.

AND

FROM

CAN

BE

is

equipped with a

DISCHARGE, one for low

OIL

PRESSURE

ALARM

LIGHT

ALTERNATOR ALARM

LIGHT

The panel also includes an alarm buzzer for low OIL

PRESSURE

or high COOLANT 'IEMPERATURE.

RPM gauge is illuminated when the KEY switch

The

is

turned on

and remains illuminated while the engine is in operation.

ALARM:

THE

BELOW

PULSATING

TEMPERATURE

210°F:(99°G}:

NOTE:

SOUNDING PRESSURE

ALARM'WILLSdUND'IF

10.:.

5·psl'(0.7.:.

SIGNAL:

IN

THE,

THIS:

ALARM

IS

NORMAL.

REACHES

0.4

THE

ALARM

THE

FRESHWATER

EVENT,

WILL·SOUND

ONCE

15

psi

kg/cni').

WILL

THE

WHEN

THE

(1.1

kg/cm'),

THE

INTHIS_

ALSO

COOLING

ALARM

THE

ENGINE

ENGINE'S'OIL

EVENfTHE

SOUND

IF

CIRCUIT

WILL

EMITA

KEY

SWITCH

STARTS

THE

AND

ALARM

WILL

TEST

PRESSED, ALTERNATOR,

PRESSURE, COOLANT TU.RE CutTS. THE OIL THE TURE LIGHTS ADDITION

ING BUZZER.

PRESSURE

ALARM

THE

RISES

CONTINUOUS

THE

PRESSURE,

THE

FALLS

WILL

COOLANT

TO

IS

TURNED

ENGINE'S

SILENCE.

BUTTON:

WHEN

TESTS

THE

AND

TEMPERA·

CONTROL

WHEN

PRESSED,

ALTERNATOR, WATER

AND

TEMPERA-

INDICATOR

ILLUMINATE

TO

SOUND-

ALARM

EMIT

A

SIGNAL.

ON.

THIS

OIL

THE

OIL

THE

CIR·

THE

IN

START

BUTION:

STARTER'S BUTTON

PREHEAT

TIME.

SOLENOID

WILL

BUTTON

WATER ALARM

WHEN

NOT

OPERATE

IS

WHICH

PRESSED

TEMPERATURE

LIGHT

PRESSED,

ENERGIZES

CRANKS

AND

HELD

THEENGINE.

ELECTRICALLY

THE

UNLESS

ATTHE

Engine_s &

THIS THE

SAME

Generators

PREHEAT

THE

TRANSMITTED

BUTTON:

CONTACTS

POWER

TO

PREHEAT

SOLENOID

IS

ALSO

TRANSMITTED

THE

TO

----KEY

WHEN

IN

THE

PREHEAT

GLOW

PLUGS.

ALSO

THE

ELECTRIC

SWITCH:

SWITCH SUPPLIES INSTRUMENT CLUSTER,

EXCITATION

.

DC

CHARGING

AND

TO

ENERGIZING

.MODE.

DEPRESSED,

SOLENOID

THE

"I"

RECEIVES

FUEL

TO

THE

START

THE

WHEN

TURNED

DC

POWER PANEL

PREHEAT

TERMINAL

ALTERNATOR

THE

ALARM

IT

tN A PULSING

IT

CLOSES

SENDING

TERMINAL

POWER

AND

PUMP.

DC

BUTTON.

KEY

ON

TO

THE

SWITCH,

OF

BUZZER

ON

THE

THIS

IS

POWER

THE

9

STARTING/STOPPING

PROCEDURE

THE

STARTING

The models in this manual have a 12V assisted by a weather starting. The air heater heats the engine providing a rapid start with less wear on the starter.

The start must be depressed for the time specified Then, while keeping the START button is depressed to crank the engine.

circuitiy is designed so that

Starting

1.

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

CAUTION:

in

neutral. damage vessels

2. Tum the KEY

3. Depress the instrument panel will energize.

pulse and the electric fuel Preheat button should be depressed in accordance with the following chart:

SYSTEM

DC

electric starter

DC

air intake heater for both normal and cold

the

PREHEAT button

in

the preheat chart.

PREHEAT button engaged, the

Procedure

Make

certain

$,tarting

to

your

transmission,

nearby.

SWITCH

PREHEAT button and hold it.

in

the

gear

to the

pump

transmission

could

result

your

boat,

ON

position (2 o'clock).

The

alarm buzzer will

will energize.

intake air,

is

in

serious

and

The

.

Temperature/Preheat

Atmospheric

____

41°F(5°C)

23°F(-5°C)

limit

NOTE:

The START button will not energize unless the PREHEAT button button activates the glow plugs the

PREHEAT intennittently

plugs.

4. While still depressing the PREHEAT button, depress the

START button. This will engage the starter solenoid. When the engine starts, release preheat button. oil pressure reaches

NOTE:

When starting:

A voltage drop will occur

when the preheat button is

depressed.

Temperature

or

to

23°F

or

of

continuous

Preheating

higher

lower

is

The

.

---+---

(-5°C)

__

use

depressed. Depressing the PREHEAT

to

pulsing alarm will silence once the

5-10 psi.

Approx.

1--

Approx. Approx.

30

seconds

in

the cylinder head so use

avoid overheating the glow

the

start switch and

10

seconds

15

seconds

20

seconds

before

Time

cranking

S. Should

CAUTION:

engine

filling

pump

cooling enter manifold happening shutoff,

cause resulting

issue;

6. Once oil pressure and battery charging voltage.

NOTE:

--

Starting

Make sure the lubricating oil is appropriate for the prevailing

temperature. the Specifications section

The battery should Use

Temperature/Preheat chart elsewhere in this section.

Stopping

To stop place the transmission a few moments to stabilize temperatures. OFF panel and engine, de-energizing the fuel injection pump, stopping fuel flow from engine.

Make certain the key switch ( 12 o'clock). discharge.

operator

of

preventing the battery from discharging

key from the key switch after stopping the engine.

the

engine not start when the START button is

10

to

20

depressed for

30

wait longer.

seconds; repeat the procedure above and preheat

Never

run

Prolonged

starting

with

is

pumping

system

the

draining

of

the

engine is running.

NOTE:

engine. Depressing the second intervals will help stabilize the engine rpm until the engine operating temperature reaches 170 (77

- 88°C)

When the engine is running depressed, a charging load on the DC alternator will be discernible.

a sufficient

can

raw

water.

raw

during

engine's

once

the

by

closing

the

excessive

from

raw

owner/operator

engine starts, check the instruments for proper

Never attempt

Some unstable running may occur

and

Under

Cold

Use

oil with an API an,

be

amount

seconds, release both buttons and

the starter

cranking

result

This

water

cranking. cylinders exhaust

the

exhaust

engine

water

to

a propeller load is applied

for

more than 30 seconds.

intervals

in

the

engine

may

happen

through

This

by

way

system

raw

water

muffler,

cranking.

entry

is

not a warrantable

should

engage the starter while

PREHEAT button for

keep

and

without

exhaust

because

the

raw

water

raw

water

of

the

exhaust

fills.

Prevent

supply

through-hull

and

correcting

Engine

this

in

mind.

in

a cold

10-15

to

the PREHEAT button

the

system

the

can

this

from

damage

the

- 190° F the engine.

Conditions

SAE

rating as specified in

of

this manual.

fully charged to minimize voltage drop.

of

preheat to aid

in

starting. See the

the

Procedure

the

engine, bring the throttle to an idle

in

neutral. Allow the engme to idle for

position. This opens the

If

the key switch is left

An

engine alann buzzer is provided

of

this condition (key switch

DC

is

in the OFF position

circuit to the instrument

ON,

ON).

~ositio?

Tum

the key to the

~olenoid

1t

the battery will

on.the

and stoppmg the

to

warn the

The best method

is

to remove the

and

is

Engines & Generators

10

DESCRIPTION

Although hour

of test operations assembly ated

properly,

your

engine and

serviced

Breaking-in a new

ton

rings

to

and

smoky

scored,

which

break-in Your

conditioning to Perform lowing:

1.

2.

period.

new

maximize

this

Start

the

DURE

that

all

charging) Allow

fast

idle)

the

130-

·

your

engine

procedures

a break-in time

is

dependent

during its initial 50 hours of

engine basically involves seating

the

cylinder

operation indicate that

is

cause<!

engine requires approximately 50

operation the performance conditioning carefully, keeping

engine according

section.

systems (raw water pump, oil pressure, battery

the

Run

are functioning.

engine

until

the

140°F

ENGINE

has

experienced a minimum of one

at

the

factory

to make sure accurate

were

followed

upon

walls.

by

overloading the engine during

to

break

the engine at fast idle while checking

to

warm

water

temperature gauge

(55 -60°C)

and that the engine oper-

is

required. The service life of

how

the engine is operated

use.

Excessive

in

and

to

the

up

(preferably

range.

oil

the

cylinder

each moving part in order

service life of the engine.

STARTING

BREAK-IN

the

consumption

walls

hours

of initial

in

mind the

PROCE-

by

running at

moves

are

pis-

fol-

into

the

PROCEDURE

3.

While

using

the vessel, run the engine at

speeds

for

the first

idling.

4.

Avoid

rapid acceleration, especially with a cold

5.

Use

caution not

grey

or

black exhaust and the inability of

reach

its

full

6.

During

the next varying Avoid

engine speeds, with short runs at

prolonged idling during

CHEGKLIST

0 Monitor

D Check

0 Check

vibration

0

Confirm When When When

NOTE:

break-in information

the

for

leaks of

for

abnormal noise such

and blow-back sounds.

exhaust smoke:

the

engine

the

engine is warm - almost smokeless.

the

engine

See

the

TRANSMISSION section

25

hours.

to

overload the engine. The presence of a

rated speed

25

hours,

control panel

fuel

is

cold - white smoke.

is

overloaded -some

on

your transmission.

Avoid

are

signs of

the

engine

this

gauges.

and engine

as

various

engine

prolonged periods of

engine.

the

engine

to

an

overload.

may

be

operated

full

rated

rpm.

break-in

oil.

knocking, friction,

black

of

this

period.

smoke

and

manual for

at

soot.

Engines & Generators

11

THE

DAILY

OPERATION

CHECKLIST

Follow

this

check

list each

D Record D

D Check

D Check D Check

D Check

O Look

D Check

the

hounneter reading in your log (engine hours

relate to the maintenance schedule). Visually

Periodically check the manifold coolant level.

turned

transmission

mounting

inspect the engine for

the

oil level (dipstick).

the

coolant level in the coolant recovery tank.

the

transmission

your

diesel

on.

for

clean

bowl.

for

loose

is

s~ure.

the

starting batteries (weekly).

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

D Check that

secure.

the

raw

the

day

fluid

fuel

supply and that the fuel valve is

fuel

in

the

wires

at

the alternator and make sure

water pump

raw

water thru hull

before starting your

fuel,

oil, or water leaks.

level.

fuel filter/water separator

to

make sure its mounting

is

open.

engine.

.·

its

is

STARTING

NOTE:

manual

1.

~t

NOTE:

neutral energizing transmission energize.

2.

Tum

3.

Depress

4.

While fires,

5. Hold and/or the alarm shuts

NOTE:

engine. temperature

NOTE:

then

6.

Allow a few fortable rpm,

THE

See

STARTING/STOPPING

for

more

the

transmission

Hydraulically

safety

circuit

the

KEY

PREHEAT

pressing

release

PREHEAT

Some

This

Should

repeat

rpm (approximately

and

get

ENGINE

PROCEDURE

detai~ed

switch

is

START.

unstable

condition

is

the

minutes

underway.

instructions.

in

neutral, throttle advanced.

operated

through

passes.

in gear

to

the

ON

(10

PREHEAT,

until the oil pressure reaches

running

reached

the

engine

above

prpcedure,

for

tra:zsmissions

which

This

switch

so

the

starter solenoid

position

to

15

seconds).

push

off.

may

should

abate

and

loads

fail

to

the

engine

1000

START.

start,

the

is

(2

o'clock).

occur

as

are

r;ipplzed.

wait

and

PREHEAT

to

rpm),

have a .

staner

ope~

wh.en

will

As

the

in

a cold

non;ial

30

seconds,

warm

at a

then

teduce

in

this

solenoid

the

not

engine

15

psi

operating

longer.

·comthe

Engines & Generators

12

WARNING

ALTERNATOR

The

Captain

with

a

red

The

Admiral

petfonnance

COOLANT

A coolant'temperature switch housing.

coolant's

(99°C).

AIR

WARNINGS

Control

warning

Panel indicates alternator

light.

Control Panel uses a voltmeter of

the

alternator.

TEMPERATURE

This

switch

wilt

activate a continuous

operating

BLEED

temperature reaches approximately 210°F

PETCOCK

LIGHTS,

SWITCH

is

located

low

to

monitor

on

the thermostat

alarm

.;·

ALARMS & CIRCUIT

LOW

OIL

PRESSURE

A

low

oil

discharge

·

the

if

the

oil

pres~ure.

(0.7

pressure alarm switch

gallery.

This switch's sensor monitors

Should the engine's oil pressure

- 0.4 kg/cm

.

2

),

this

---~(~

BREAKER

ALARM

s.witch

SWITCH

is

located off

will

activate a

the

engine's

fall

pUlsatinJ?

the to

engine's

oil

10-

5

alann

~~

/'

osi

COD

LANT TEMPERATURE SWITCH

ENGIJIE

The mounted Excessive

the breaker because this After engine.

CIR8UIT

DC

harness

manuaf reset circuit breaker (20 amps

current

instrument

to

trip.

the

should

occur,

repairing

.on

panel

In

opened

tlie

IRBAHIR

the

engine

is

protected

draw

or electrical overload anywhere

wiring or engine wiring will cause

this

event most engines will shut

breaker disconnects the fuel

check

and

repair the source

fault,

reset the breaker and restart

by

an

DC).

of

engine-

down

supply.

the

problem.

the

in

the

If

~--

·~--

i:'.

SPIN-ON

OIL

FILTER

...

--~·'

-

-·

Oil

PRESSURE

SEND

OR

,....,-···.

....

~~

'

'•0)

--.

20

AMP

CIRCUIT

BREAKER

~

N

•+..,.,

l

"

lwiWEB7ERBEKE

Engines & Generators

-

13

A

WARNING:

and

gloves,

ctJntrol

panel,

"'l

111

NeviJI'

use

the

tum

aftempt

correct

11"

the

to

perform

tools

banery

MAINTENANCE

any

service

while

the

engine

for

each

job.

When

switch~

servicing/replacing

SCHEDULE

Is

running.

Wear

DC

components,

the

proper

tum

safety

o"

the

equipment

DC

circuit

Sllth

as

breaker

goggles

on

the

SCHEDULED

I

OAILYCHECK

Coolant Engine Fuel/Water

Fqel

Visual

Drive

'INITIAL

Engine

*Exhaust

Engine

and

•1Head Bolt Torque/ Adjust Valves

*Fuel

Engine Transmission Heat

MAINTENANCE

BEFORE

Level

Oil

Level

Separator

Supply

Inspection

Belts-

Oil

Throtlle,

Shutoff

RHer

Idle

Exchanger

50

HOURS

and

Riter

System

Lever

Speed

fluid

of

TransmisSion

Cables

START-UP

(owner

installed)

Engine

OF

OPERATION

EXPLANATION

Check

Oil

level

Check hours

·

Use

properly

there

is

Check securing connections.

Inspect

Initial

engine

Initial

check Check Check

Check

Torque

Initial

change,

Refer

to

Initial

change,

Open

end

interval

OF

at

recovery

tank

should

indicate

for

water

ar~d

or

once a year.

filtered

adequate

fuel

for

fuel,

oil

and

v-clamp

is

Look

for

frayed

edges.

oil

and

at

50 that the

Check

Bolts and

for

hours,

the

exhaust

integrity/mounting

all

connections

thefT

Specifications.

then

caps

and

your

area.

SCHEDULED

•.

if

between

dirt

112

diesel

for

water

tight

for

loose

filter

hoses

Adjust

every

at

300

clean

MAINTENANCE

empty,

check MAX

in

fuel.

Drain

with

the

vessel's

and

exhaust

No

exhaust

bolts/hardware

Belts

must

change

at

then

every

are

properly

security

are

secure,

Valves

(cold)

250

hours

or

out

debris.

at

manifold.

and

LOW

on

filter

if

necessary.

a

Cetane

rating

needs.

leaks.

leaks

be

50

250

or

once a season.

Change

Check

around

and

properly

hours

then

hours

or

attached

of

the

water

proper

travel

once a year.

zinc

correct

tensioned

Add

coolant

dlpstick.

Do

Replace

of

#45

or

higher.

that

the

elbow.

as

neede~.

change

both

once a year.

and

that

injected

anode

the

exhaust

and

lubricate

if

necessary.

if

needed.

not

overfill!

filter

every

Check

water

injected

Inspect

-------

every

250

Garetully

securing

elbow.

with

Determine

that

wiring

hours.

inspect

clamps

WD-40.

250

operating

exhaust

and

electrical

for

are

zinc

elbow

leaks.

tight.

service

I

EVERY

*Drive

(Fresh

Starting

"Electric

Zinc

Anode

I

EVERY

Air

Intake

Heat

Key

Swilt:h

*Drive

(Fresh Starting

Electric Raw Engine

50

OPERATING

Belt

WaterJRaw

Batteries

fuel

Pump

100

OPERATING

Filter

Exchanger

(Instrument

Belts

Water/Raw

Batteries

Fuel

Pump

Water

Pump

Oil

and

Riter

Water

HOURS

Pumps)

HOURS

Panel)

Pumps

OR

MONTHLY

OR

YEARLY

as

applicable)

Inspect

for

slipping,

Check

electrolyte

off

corrosion

Inspect,

no

Inspect

and

your

own

Inspect,

Clean

Inspect

and

anode

needs

Replace

zinc Lubricate Inspect

for

slipping,

Check

electrolyte

off

corrosion

Inspect,

no

Inspect

impeller,

Change

the

proper

tension

cracking

levels

if

needed.

leaks.

Connections

clean

zinc

inspection

and

replace

clean

zinc replacing, if

necessary.

with

"lockeze".

proper

tension

cracking

levels

if

needed.

leaks.

Connections

check

engine

oil

(3/8'

and

wear.

Make

sure

Apply

petroleum

anode.

Replace

schedule.

as

needed.

anode.

Note

you

should

(3/8"

and

wear.

Make

sure

Apply

drive

shaft

and

oil

filter

to

112"

deflection)

Adjust

tension

cables

are

clean

if

the

condition,

remove

to

112'

deflection)

Adjust

tension

cables

petroleum

are

clean

security.

(always

and

or

replace

and

connections

jelly

to

terminals

and

tight

Glean/replace

necessary.

then

the

end

and

or

replace

and

connections

jelly

to

terminals

and

tight.

Inspect

together)

adjust

if

needed.

as

needed.

are

in

good

for

corrosion

filter

Note

the

condition,

determine

cap

adjust

Clean/replace

there

and

as

are

for

is

your

clean

if

needed.

in

good

corrosion

filter

no

shaft

Replace

order.

element

then

own

out

the

Replace

order.

element

water

Check

belt

cover.

Clean

protection.

if

applicable.

determine

schedule.

debris.

Check

belt

cover. Clean

protection.

if

applicable.

or

oil

sealle~ks.

If

zinc

Engines & Generators

14

NOTE:

Use

the

engine

MAINTENANCE

hourmeter

gauge

to

log

your

SCHEDULE

engine

hours

or

record

your

engine

hours

running

time.

SCHEDULED

I I

EVERY

250

Transmission

Fuel

FiRer

and

Inlet

Fuel

Filter

DC

Alternator

*Electric

Fuel

*Vibration

*Exhaust

I

EVERY

*Fuel

*'Head

*Starter

*Preheat

*Engine/Shaft

~eat

Exchanger

ElbowJExhaust

500

Injectors

Coolant

System

Bolt

Motor

Raw

Water

Circuit

Crank

Case

Isolators/Engine

MAINTENANCE

OPERATING

D-Rings

Pump

OPERATING

Torque/Adjust

Pump

Alignment

Vent

HOURS

Mounts

System

HOU"S

Valves

OR

YEARLY

OR

YEARLY

EXPLANATION

Change Remove Remove Check

mounting Inspect, Check

vibration Inspect Check

the

of

the

exhaust chaffing.

NOTE:

An

Check

and

Drain,

flush

Torque Bolts and Adjust Valves (cold)

Check

motor

Remove

components

Lubricate Check

compounds Check Clean

crank

Replace

fluid

at

300

and

replace

and

replace

no

leaks.

isolators,

zinc

anode

structural

system

No

exhaust

adjust

and

solenoid

and

pinion

drive.

from

engine,

showing

when

re-assembling.

operation

on

threads.

security

of

case

filter

element

OF

SCHEDULED

operating

bracket,

Connections

replace

integrity

leak

injection

re-fill

motor

of

the

vent

hours.

fuel

filter

and

inlet

fuel

filter:

tighten

brackets

if

necessary.

of

attached

leaks.

Hoses

will

cause

opening

the

cooling

for

corrosion.

remove

cover

wear.

If

needed,

pre-heat.

shaft

coupling

components

as

needed.

MAINTENANCE

Lubricate

all

sealing

electrical

are

clean and

the

water

to

the

and

exposure

pressure

system

and

Remove

and

located

control

0-rings.

connections.

and

tight.

mounting

injected

elbow.

All

muffler

are

to

diesel

and

with

appropriate

Remove

inspect

replace

impeller

and

clean

check

inside

cable

Clean/replace

hardware.

exhaust

connections

in

good

exhaust!

spray

conditions.

and

lubricate.

cam

and

the

glow

alignment.

the

rocker

elbow serviceable

antifreeze

wear

hose

shaft

and

check

filter

Replace

casting.

should

Clean

plates.

gasket.

plugs.

cover

..

attachment.

element

as

needed.

Check

be

secure.

condition.

mix.

and

lubricate

Replace

Re-install

.

if

applicable.

the

integrity

No

the

any

with

anti-seize

starter

EVERY

1000

OPERATING

*Heat

Exchanger

Crankcase *Fuel *Transmission

*Starter

*Transmission

NOTE:

*WESTERBEKE

Ventilation

Injectors

Motor

Keep

the

Oil

Damper

engine

recommends

Valve

Cooler

Plate

surface

HOURS

(as

applicable)

clean.

this

OR OR

Dirt

and

service

EVERY

oil

will

be

performed

FIVE

inhibit

YEARS

Remove antifreeze

the

engine's

by

an

knowledgeable

the

heat

and

Disassemble Pressure Remove Remove, Inspect

indicatloQ

the

ability

and

test

and

have

clean

damper

of

damper

to

remain

exchanger

flush

clean.

injectors/re-build

professionally

and

mechanic.

the

system.

Replace

lubricate

plate,

replace

spring

cool.

for

at

the

wear).

professional

as

needed.

1500

hours.

tested

and

cleaned.

drive.

if

necessary

cleaning

(damper

and

plate

pressure

chatter

testing.

at

idle

Change

speed

is

the

an

l-.Y'lWESTEFlSEKE

f Enttlnes & Generators

15

DESCRIPTION

Westerbeke for

fresh bustion which water parts, from

exchanger, water fresh ferred tube exhaust other coolant transferred fresh

each allows harmful

FRESH

NOTE:

ommended

fresh

Fresh

lating then heat block

marine

water

cooling.

and

friction

circulates coolant and

the

fresh water

flows

water

to

the fresh

walls

system

words,

is

water

other.

the

deposits.

throughout

cools

the engine

similar

through

coolant

to the

where

the engine

cooled

heat

overboard

cool~nt

Using

cooling

WATER

Refer to the

antifreeze

water coolant.

water coolant pump,

absorbing

passes

through

exchahger

via

where

the suction

diesel

is the

in

flows

water

raw

by

and

only

water

COOLING

ENGINE

engines

Heat

transferred

the

engine

oil.

The

coolant

function

the

tubes

around

coolant

water

which

finally

is

cooled

raw~

water,

through

raw

fresh

passages

and

water mixture

is

pumped

heat

the

thermostat

it

is

cooled,

side

of

are

designed

produced

block,

heat

to

of

it

water

to

fresh

engine.

its

is

transferred

raw

water

an

automotive

the

heat

the

tubes;

is

conducted

is

then

is

discharged by

fresh

and

the

the exhaust

circuits

coolant

to

stay

in

CIRGUIT

COOLANT

through

from

the

engine.

into

and

the

circulating

and

the

engine

water

'This

circulating

internal

by

means

exchanger

engine

through

pumped

overboard.

water

raw

water

are

independent of

within

clean

section

to

be

used

the

engine

The

the

manifold,

returned

pump.

CODLING

equipped

by com-

coolant

fresh

moving

externally

of a heat

radiator.

coolant,

system.

and

for the

to

Raw

while

heat trans-

the

into

the

In

this

carries

The

the

engine

free

from

rec-

as the

by

a circu-

coolant

to

the

engine

SYSTEM

the

When

the

engine

vented

by

the

closed

is

bypassed

manifold

thermostat

coolant

cooling

Coolant

A coolant

and cant ing

system.

engine

CHANGING

The

MAINTENANCE

become

.A

critical; a

traced

To

drain and Releasing help

A

Wear

around

from

overheating).

gradually

to

flow

system.

Recovery

recovery

contraction

loss

of coolant

'This

manifold

COOLANT

engine's

coolant

contaminated,

GAUlflON:

substantial

back

the

engine

remove

the

coolant

the

coolant

WARNING:

protective

is

started cold, external

thermostat (although

the

thermostat

As

opens,

allowing

unrestricted

to

the

tank

allows

during

engine operation,

and

without

tank

should

be

level

and

should

must

be

changed

SCHEDULE.

it

can

lead

Proper

cooling

number

to

cooling

coolant

flow.

system

coolant,

drain

Beware

gloves.

Loosen

located

on

of

coolant.

some

to

prevent

the

engine

external

for engine coolant

introducing

located

be

easily

If~

to

overheating

system

of

engine

tl:ie

warms

full

flow

portion

without

air

at

or

accessible.

according

coolant

maintenance

failures

above

corrosion.

the

manifold

on

the

engine

the

heat

exchanger

the

hot

engine

flow

coolant

exhaust

up,

of

the

engine's

of

expansion

any

into

the

to

the

is

allowed

problems.

can

pressure

block.

will

also

coolant.

is

pre-

flow

the

signifi-

cool-

to

is be

cap,

.EllGINE

Engines & Generators

COOIART

.

DRA!it

ENGINE

~

,./'~~

./

BLOCK

16

COOLING

SYSTEM

Refilling

After exchanger's coolant coolant

the

NOTE:

When a steady the

Monitor

the sure Remove

coolant the flow

After

Coolant engine needed.

RECOVERY

the

Coolant

replacing

manifold,

Open

petcock and fill

manifold

cap.

into

checking

TO

COOLANT

into

the

mix

Run

the

should

cool$

Clean

TANK

the

manifold

start

the

air-bleed petcock

flow

coolant

to

the

cap

on

to

halfway

the

engine

recovery

for

draw

down.

up

engine

bl9ck drain

petcock.

the

of

the

in

filler

the

leaks,

Add

any

Then pour clean, premixed

and

when

engine

and

coolant appears at

system

until

the

~anifold

neck

and

coolant recovery between

and

observe the coolant expansion

tank.

stop

the engine

bade

into

'the cooling system

coolant

spilled

coolant. ·

KEEP

COOLANT

CLEAR

plug,

the

coolant

run

it

at

on

the

iieat

the

manifold

and

add

install

LOW

and

to

the

recovery tank if

THE

PASSAGE

dose

the

heat

is

visable

slow

idle.

exchanger.

the

petcock,

as

the

manifold

tank

and

MAX and replace

and

allow it

remains

needed.

fill

as

close

pres-

with

to

the

in

full.

Fill

cool.

Replacing

Remove ing

as

ket,

apply a thin before screws

Run

the

there

the

shown.

pressirig ..

engine

are.no

the

cap

When

leaks

THERMOSTAT

ASSEMBLY

Thermostat

screws

and

disassemble

installing

coat of sealant

it into place. Do

and

check

at

the

for

normal temperatures

thermostat housing.

new

thermostat

on

both sides of

.not

over-tighten

the

thermostat

and

gas-

the

gasket

the

cap

and

·AIR

BLEED

PETCOCK

hous-

that

FROM

COOLANT

RECOVERY

NOTE:

pressure

good

the closes cap.

<;oolant coolant able

to

TANK

Periodically

cap.

condition.

vacuum

tightly.

Check

passage

within

to

expand

and

from

check.

Ensure

the

Check

valve

opens

Carry a spare

also

to

ensure

is clear

the

system

and

contract

the

coolant

THERMOSTAT

A

thermostat,

engine,

uously engine from

flowing thermostat As

~he

thermostat replaced

located

near

controls flows is

engine

the

coolant temperature

through

first

to

is

easily.

the

started,

(some

coolant

prevent

warms

acces~ible

Carry a spare

COOLANT

EXPANSION

PRESSURE

/CAP

~

COOLANT

the

upper and lower rubber seals

to

ensure

and

the

so

is

recovery

the

closed

the

closed thermostat prevents coolant

the

exhaust manifold

up,

the

and

RETRACTION

condition

manifold at

is

by-passed

thermostat

can

thermostat

of

the

tank.

the

as

the coolant

cooling circuit When

through

from

gradually

be

checked, cleaned, or

and

manifold ·

front of

a hole

overheating).

opens.

gasket.

are

SEAL

the

contin-

the

in

The

in

the

N~111

...

J

"b/J,,,.

-

-~

RAW

WATER

The

raw impeller water source (ocean, lake, or river) through a

water

strainer. through the

heat exchanger

..

ing

fresh

into

the water-injected exhaust

ing

the exhaust gasses.

water

is discharge pressure.

Raw

Water

The

raw

non-ferrous housing and a neoprene

has

flexible within the impeller housing, producing On

no

account should this pump be lubricant impeller

Raw

water

water)

is

are

not

raw

water

NOTE:

Should a failure occur with

(seals

and bearings), it may

chase a new

COOLING

water

flow

pump.

This pump draws water directly

The raw water passes

the

raw

water pump

water coolant. The raw water

discharged overboard

CIRCUIT

is

created

tubes}

by

a positive displacement

to

the

heat exchanger

where it cools the engine

elbow,

Tirls

mixture of exhaust

by

the engine's exhaust

from

is

mixing

then

Pump

water

pump

is a self-ptiming, rotary

impeller.

vanes which wipe against a

for

the

imp~ller.

and

impeller cover gasket

pump impeller failures occur

not present during engine operation. Such

warrantable,

flow

is present

pump and rebuild

There should

and

operators are cautioned

at

start-up.

be

more

the

curved

the

run

dry

always

(an

impeller

when

the

pumps internal

cost efficient

original

from

hose

the

strainer

discharged

with

gas

pump

The impeller

cam

pumping

as

water

be a

kit)

lubricant

to

pump

the

to

the

(through

circulat-

and

cool-

and

raw

gas

with

plate

action.

acts spare aboard.

(raw

failures

make

parts

to

pur-

as

a

spare.

raw

a

as

sure

a

w

WESTERBEKE

Engines & Generators

17

COOLING

SYSTEM

Changing

Close and,

with impeller Move push

the bling, gasket.

Y®

-!

l.

the

raw

water

the

aid

out of

the

blades

impeller

apply a thin

Open

the

Raw

Water

intake

of

two

pump.

to

conform

into

the

coating

raw

water intake

Pump

Impeller

valve.

Remove

small

screwdrivers, carefully pry

Install

the

to

the

curved

pump's housing.

of lubricant

valve.

new

impeller

to

the impeller

the

cam

When

pump cover

and

gasket.

plate

and

assem-

and

'-

GASKET

NOTE:

Also

follow

the

above

the

aground.

If

the

engine temperature

normal

reading,

may

have

been

raw

waier through

..

the

cause

caught

the

~

procedure

gauge

may

be

up

in

the

cooling system.

after

having

ever·shows a higher

that silt,

strainer, slowing

leaves

or

the

run

than

grass

flow

hard

of

WASHEil~

STRAINER

FILTER

TYPICAL

RAW

WATER

owner

INTAKE

lnstalle~

STRAINER

.

A

CAUTION:

Impeller,

coollng

circuit.

exchanger.

Raw

Water

NOTE:

Always

.

the

strainer

A

clean

taw water engine's strainer in

Perfonn

operation:

1.

2.

3.

4.

5.

6.

7.

cooling

when

the

glass

the

Close Remove Clean Replace Reassemble Open

Run

the

they

Intake

install

will

making

should

following

the

raw

and

the

glass.

the

seacock.

engine

If

any

of

must

be

found

They

often

Strainer

the

strainer at or

always

be

intake

strainer

system.

clean

washer

and

Include a

your

be

clear.

maintenance after

water

seacock.

the

if

necessary.

install

and

check

the

vanes

have

to

prevent

can

be

found

below

self-priming.

is a vital

visual

periodic engine

strainer

the

for

filter.

strainer.

leaks.

bro~en

blockage

In

component of

inspection of

check.

every

the

waterline

100

off

the

In

the

heat

the

this

The water

hours of

so

·

HEAT

EXCHANGER.

The heat exchanger is a copper cylinder

number the

engine is circulated around the copper

removes

of small copper tubes. Raw water

small copper tubes and the fresh water coolant

heat from

HEAT

EXCHANGER

PETCOCK·-

CLEAN DEBRIS

the

fresh water coolant.

OUT

which

tubes.

is

pumped

The

ZINC ANODE

encloses a

through

from

raw

water

HEAT GASKET

the

EXCHANGER

Engines

18

&.

Generators

Zinc

Anode

Two

zinc

anodes, cooling having action reducing

the checked required.

circuit

the

taking

the

system.

monthly

Spare

'

"

NEW

NOTE:

Electrolysis action is the result

installation and vessel location; not that

or pencils,

within

the

heat exchanger. The purpose

zinc

anodes

is

to

place

in

the

raw

effects

of electrolysis

The condition of

and

the

anodes

should be carried on board.

REPLAGE

are

located in the

sacrifice them

water cooling circuit,

on

other components of

the

zinc

ano~es

cleaned or replaced

COOLING

raw

to

electrolysis

should

Gl.EAN

of

each particular

of

the engine.

water

?f

thereby

be

as

&

.

REUSE

SYSTEM

If

the

zinc

anodes need replacement, hold

which the

ening

boss from possibly tearing off

removing the zinc, poor condition, there are probably a lot of the clean the inside of exchanger end gasket aged to

your engine model's heat exchanger

ber), 0-ring

NOTE:

do not require sealant. Sealant should not be used as it insulate the zinc from the metal ing preventing electrolysis action on

Heat

After approximately and motive radiator shop should be able exchanger.)

NOTE:

that a heat exchanger cleaning be peiformed more·often than every

zinc

anode is threaded with a wrench

the

anode with another

note

exchanger. Remove the end of

all

zinc debris.

when

removing the end

and

cover, and install a

The threads

Exchanger

pressure test

Operating in silty and/or tropical waters

1000 hours.

of

the zinc anodes are pipe threads

Service

1000

the

engine's heat

wrench.

the

exchanger

the condition of

Always

in

case the present

cover.

of

hours

of operation,

the

hex

boss

while

loos-

This

prevents

it

If

zinc

the

heat exchanger

have a spare

one

Replace

end

gasket part

new

zinc

the heat exchanger hous-

t~e

zinc.

exchanger.

to

clean

shell.

After

the

zinc

flakes

becomes

the

gasket

anode.

remove, (A

local

and

test

may

the

is

within

and

the

require

into

hex

in

heat

dam-

(refer

num-

and

may

clean auto-

heat

.

DESCRIPTION

A

marine

diesel

engine running at high speed will typically consume must engine must

unrestricted air intake silencer intake

element has engine.

more

the

engine

pulsing

needs

opening

in

little if

than

room

be

unrestricted.The intake silencer flow

noise

little maintenance other that ensunng its

remains

the

silencer

any

air

born contaminates that can effect

AIR

6,000 cubic

be

into typical of a diesel engine.

unobstructed.There

to

well

ventilated,

the

engine

service.

feet

of air per

the

while

lessening

The marine environment

INTAKE I SILENCER

hour.

Not

only

air

flow

into

the

allows

fo~

the

arr

TI:e

i~tak~

arr

is

no

filter

the

lwlWESTERBEKS

I

Engines & Generators

19

FUEL

SYSTEM

DIESEL

Use No. 2D (SAE 1313) diesel fuel with a Cetane rating 45

FUEIJWATER

A primary fuel filter installed between the fuel tank and the engine water and other contaminant's from the fuel before they can be carried to the fuel system on the engine.

A typical fuel filter/water separator is illustrated below. This is the Raycor Model separator type filter is not installed between the fuel supply tank and engine-mounted fuel system, any water in the fuel will affect the fuel pump, engine filter, and injection equipment. certain the fuel reaching the engine's injection equipment is free and maintaining a proper filtration/separation system.

FUEL

The fuel injection pump and the fuel injectors are precisely

manufactured and they must receive clean diesel fuel, free from water and fuel must pass through at least two fuel filters, a fuel water

separator and the engine's spin-on fuel filter. Visually inspect,

clean, and change these filters according

schedule in this manual.

ENGINE

Periodically check the fuel connections and the bowl for

leakage. Replace the filter element after the first then follow the

FUEL

Periodically check the fuel connections to and out and make sure that no leakage is present and that the fittings are tight and secure. The DC ground connection pump's mounting bolts should the mounting bolt to ensure proper pump operation.

When energized

purge

of

FUEL

or

higher. Grade

of

diesel fuel

a~cording

to ASTM D975

SEPARATOR

of

the water separating type must

to

remove

500 MA. Keep

The owner/operator is responsible for making

of

impurities. This process is accomplished by installing

FUEL

FILTER

WATER

SEPERATOR

in

mind that

if

FILTERS

dirt. To ensure this flow

FUEL

FILTER

MAINTENANCE SCHEDULE.

LIFT

PUMP

air from the fuel system and provide a continuous flow

fuel

as

the engine is running.

(#039275)

be

thru

the preheat circuit, the fuel lift pump will

of

clean fuel, the

to

the maintenance

50 hours

.

of

at

one

clean and well secured by

of

be

a water

the pump

of

the

..

SOLID.STATE.

PN:

,-

030200

I

FILTER/ELEMENT

Changing/Cleaning

1.

. Shut off the fuel supply.

Unscrew the retaining ring and lower the

2. filter bowl

not to spill fuel).

3. Clean the element.

4. Replace the sealing

the bowl ing ring onto the housing carefully so as not to cross thread.

Open the fuel supply and run the engine to

5. inspect for leaks.

SERVICING

(Earlier

Change the filter/element after the first ating hours the follow the MAINTENANCE

SCHEDULE.

1.

Remove the cylinder base with an open end

wrench. Twist the base to open.

2. Install a gasket.

3. Reinstall the base by twisting it the locking tabs.

away

bowl

to

the

FUEL

Models)

new

PN:

the

Filter

Element

from the housing )careful

· ·

and replace the filter

O'ring

and assemble

housing. Thread the retain-

LIFT

PUMP

filter/element and a

030548

w/GASKET

(#301385t

off

the locking tabs

new

back

r

FILTER

I

ELEMENT

50

L

L.

BOWL

oper-

onto

Engines & Generators

20

TWIST

BASE

ON

FUEL

INJECTORS

In

case of severe vibrations and detonation injectors checked and overhauled injection service loss

of positive

in

injector faults. Since fuel injectors must be serviced

clean

room enviroment; it is best

injector Before.

base

· falling down into out easily the free

The injector washer. replaced with a

installed.·

Injector

as

removing

of

the

injector side-to-side with the aid of the socket

it,

and

This washer should

to

Cylinder

center.

Poor fuel quality,

fuel

pressure to the injection pump

a spare should a problem occur.

$e

old injector, clean the area around

injector

and

then

is

held

lift it out.

seats

new

Head

to

help prevent any rust or debris

the

injector hole.

in

by

in

the cylinder head

washer when

Tightenlftg

by

to

carry at least

If

carbon build-up or

be

removed

the

Torque

noise,

an authorized

ccintaminants

the injector

on a copper

with

new

injector

40

± 4

ft-lb

FUEL

have

fuel can

one

will

the

like,

wrench

sealing

the

injector

is

(5.5 ± 0.5

SYSTEM

the

and

result

in

a

extra

the

from

not

lift

work

to

and

kgf-m)

FUEL

INJECTION

The

fuel

injection

the

diesel

engine,

fuel

injection owner-operator requires

injection

ble

and

The

only

the

fuel

speed

servicing,

pump

repair

adjustment

inje,ction

(see

IDLE

pump

is

service

it.

ADJUSTMENTS).

PUMP

pump

is a very

requiring

cautioned not

remove it

pump

SPEED

the

has

been

facility.

the

servicing

is

the

ADJUSTMENT

important

u11nost

care

thoroughly

to

and

Do

adjustment for

bench-tested

attempt.ti:>

take

it

to

not

attempt

mechanic

.

component

in

handling.

service

an

authorized

to

·

should

engine

under

ENGINE

of The

and

it.

Ifit

fuel

disassem-

make

idle

the

to

DESCRIPTION

The

glow

plugs

are

wired through the preheat solenoid.

When

PREHEAT

"click"

should

,

INSPECTION

To

inspect the plug, remove the electrical terminal connec-

tions,

then unscrew or unclamp each plug from the cylinder

head.

Thoroughly clean each plug's tip and

brush'a114.

soft

-oil

depo~ts.

burn

erosion;

is

pressed at the control panel this solenoid

on

and the glow plug should begin

threads

cleaning solution

While.cleaning, examine the tip for wear and

if

it has eroded too much, replace the plug.

to

remove all the carbon and

TESTING

An

accurate Touch other plug used an

ammeter

A

ta

the

testing

way

to

test glow plugs is with an

one

prod

to

the

glow plug's wire connection, and the

to

the

body of the glow plug, as shown. A good

will

have a _1.0-1.2.

with

the

plug in or out

to

test the power drain 10-12 amps per plug).

WARNING:

touch.

Be

the

plugs.

ohm resistance. This method can

of

the engine.

These

glow

plugs

will

careful

not

ta

burn

your

ohmmeter.

You.

can also

became

lingers

GLOW

to

get

hot.

with a

glow

use

very

hat

when

PLUGS

be

·

A

WARNING:

·

th;in

30

Glow

Plug

Tightening

Do

not

st1eonds.

Torque

_·TESTING A GLOW

WITH

AN

OHMMETER

keep a glow

7

-11

ft-lb

(1.0

PLUG.

plug

on

tor

-1.5

m·kg)

TERMINAL

.END

TIP

more

Re-install the plugs plugs should get seconds. circuit. When reinstalling pound

If

the

on

the threads.

very

plugs

in

the engine

hot (at

don't heat

Jhe

and

the

terminal

up

glow plugs,

test

quickly,

them end)

check

use

again.

within 7 to

.for a shon

anti-seize

The

l)

com-

Engines & Generators

21

TESTING A GLOW

USINP

A

TEST

LIGHT

PLUG

ENGINE

LUBRICATING

OIL

LUBRICATION

Oil

SEN

OIL

FILTER---

OIL

PRESSURE

RELIEF

VALVE

OIL

PUMP/

ENGINE

1.

Draining the Oil Sump. Discharge the used oil through the sump drain hose (attached to the front while the engine is warm. Drain the used oil completely, replace the hose in its bracket,

securely.

DIAGRAM

PRESSURE

DOR

____

___-

Oil

CHANGE

of

and"

replace the end cap

the engine)

OIL

SCREEN

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

NOTE:

Do not punch this hole without first loosening

.filter to make certain it can be removed.

Place some paper towels and a plastic bag around the

ter when unscrewing it to catch any oil left (Oil or any other fluid on the engine reduces the engine's cooling ability. Keep your engine clean.) Inspect the old oil filter

sealing gasket comes off with the old oil

ber sealing gasket remains sealed against the filter bracket, gently remove it.

SPIN

TURN

Oil Filter. When removing the used oil

of

the old filter to drain the

as

it

is

removed to make sure that the rubber

ON

FILTER

ON

HAND

TIGHT

it.

in

the

filter.

APPLY

WHEN

This helps

If

fil-

in

the

fil-

filter.

this rub-

CLEAN

ENGINE

INSTALLING

Oil

BMM

11/16

INCH

SOCKET

NOTE:

Thread size

114

NPT.

is

Always observe the used oil as it is removed. A

yellow/gray emulsion indicates the presence the oil. Although this condition is rare, it does require prompt attention to prevent serious damage. Call a qualified mechanic should water be present in the oil. Raw water present in the oil can be the result exhaust system attached to the engine and/or a siphoning of

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

for

the lube oil drain hose capped end

~OIL

of

maintenance.

DRAIN

HOSE

of

water in

of

a fault in the

is

often

an anti-siphon valve, its poor

When installing the gasket's sealing surface on the bracket free

apply a thin coat on the new oil filter.

filter nipple on the oil filter bracket, and then tighten the

filter firmly by

NOTE:

Generic filters are ial standards parts might be entirely different from genuine parts. Immediately after engine to make sure the oil pressure is normal there are no oil leaks around the new oil filter.

3. Filling

After refilling, run the engine for a few moments while

the

Oil

cap on the top

checking the oil pressure. Make sure there is no leakage around the new oil filter stop the engine. Then check the quantity of oil with the lube oil dipstick. Fill to,

the dipstick, should the engine require additional oil.

new

oil filter element, wipe the filter

of

oil and

of

clean engine oil to the rubber gasket

Screw the filter onto the threaded

hand.· ·

not

recommended, as the mater-

or

diameters

of

important items on generic

an oil filter change and oil fill,

Sump.

Add

new oil through the oil filler

of

the engine

or

through the side oil

or

from the oil drain system,

but

not over the high mark

and

run

oil

the

that

fill.

and

on

Engines & Generators

22

OIL

NOTE:

WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic.

DESCRIPTION

The lubricating system is a pressure feeding system using an oil pump. The engine oil oil pump, which drives the oil, oil filter, oil cooler and various lubricating points in the engine. The oil continuous

specified pressure, the oil pushes

oil pump and returns to the oil

within its specified range.

During normal operation, the oil pressure may range from 25psi (1.75kglcm) at idle upwards rated rpm.

An oil pressure relief valve is located

filter threads onto. This valve functions to maintain normal engine operating oil pressure.

Note:

A newly started (cold) engine sure up to pressure as on

the

loadplaced

then returns to the

cy~le.

70

or

low as.30 psi. Oil pressure will vary depending

is drawn

When the oil pressure exceeds the

80

psi. A

on the generator. . . . .

from

under

oil

open

sump,

warmed

the oil sump by the

pressure, through the

sump to repeat the

the relief valve in the

keeping the oil pressure

of

80psi (5.6kg/cm) at

on

the fixture the oil

may

have an oil pres-

engine can have

an

oil

PRESSURE

TESTING

NOTE:

Specification

1.

2. Start the engine and let it thoroughly warm up.

3.

4. Maintain the engine

THE

Insure that the oil meets the following standards:

Remove the oil pressure sender and then install a mechanical oil pressure gauge

Check for oil leaks at the filter and

reading.

CF

OIL

PRESSURE

or

CG-4,

SAE

rpm at 3,000 and note the gauge

30,

JOW-30,

in

its place.

pump

AP/

15W-40.

assembly.

SPIN-ON

OIL

PRESSURE

There is ap oil pressure switch oil gallery to monitor the engine oil pressure and to sound the panel alarm buzzer should a occur

will sound continuously.

OIL

PRESSURE

SWITCH

(NORMALLY

OIL

(10-5 psi).

+

.......,........._.lllJll

OPEN)

FILTER

OIL

PRESSURE

SENDER

SWITCH

co1U1ected

low

The

engine alarm buzzer is such cases

into the e.ngine',s

oil pressure issue

~YOPEN

LIFT

PUMP

i

Oil

Pressure

5.

If

the pressure does not

sure, check the lubrication system and repair

(see

ENGINE TROUBLESHOOTING).

A gradual loss bearing failure. For additional information sure readings, see

TROUBLESHOOTING

OIL

PRESSURE

When installing an oil pressure switch or sender, apply a tefion sealant oil

hole

in

SENDER

AND

A

CAUTION:

pliers, switch. Snap-on, switch

35.0

lb/in2

(3.8

kg/cm')

or

more

at

3000

come

up to the specified pres-

of

oil pressure usually indicates a specific

on

"OIL

PRESSURE

DROP"

under

...

SWITCH/SENDER

to

the threads being careful not to close off the

the sender.

SWITCH

vise

Use

Proto,

will

TORQUE

OIL

grips

or

the

correct

New

cause

PRESSURE

pipe

oil

wrenches

socket Britain leaks

and/or

9 -

13

ft-lb

(1.2

SWITCH·Oo

on

the

which

is

and

others.

switch

-1.8 m -

available

Damage

rpm.

if

necessary

low oil pres-

"ENGINE

Kg).

not

use

oil

pressure

tram

to

failure.

lock

the

Engines & ·Generators

23

JNSTALLATION

Inns

popular

ler from

~ngine

NOTE:

tnstructions

tro

instBll,

WEsTBRBEKE's tnstall

Contact

accessocy

the

engine

room

Refer

'simply

this

kit

yourWES'IERBEKE

to a more

bulkhead.

to

ENGINE

on

removing

remove the engine oil filter

remote oil filter kit

with

the oil filter

is

used

OIL

the

REMOTE

OIL

· (PN.032149)

to

relocate

the

convenient

CHANGE

oil

fil,ter.

facing

dealer

engine's

location

· ·

in

diis

111ll1'1U1Jlfor

and

as

shown.

down

as

illustrated.

for

more

infomlation.

such

thread

Always

FILTER

ROTE:

oil

as

fil-

an

on

incomct

A

iectly. .If

pass

from

failure. N there

Immediately

(OPTIONAL)

Westerbeke

i.nstall.ation

CAUTION:

valve

reaching

Pie

In

all

thB

the

and

is

.not

of

It

Is

flaws

Riter

engine

Is

no

check

responsible

the

Remote

vital

to

lnsf!lll

Jn

the

reverse

assembly

Gaoslng

all

pressaro

the

hose

for

engine

Oil

Filter.

the

direction,

will

prevent

an

lntemal

reading,

connections.

failure

oil

lines

the

engine

shutdown.

car-

ail

due

by-

to

·

lHE

OUT

CONNECTION

MUST

ATTACH

CONNECTION REMOlE

TO

ATTllE

mL

FILTER.

Cylinder

Head

Crankshaft

HDIE

THE

IR

Pulley

APPLY A THIN

INSTALLING

THIS

TIGl!lEN

AN

ADDmllllAI.

CONTAC'IS

THE

Bolt

(See

MB

Nut

C;OllT.OI'

ctEAN

Kit

THREAD

BASE.

. •

(M10)

(M12)

the

Torauing

indicates

OIL

TO

THEO.RING

THE m ON,

AFTER

THEN

TllE

O.RJNO

3/4

TURN

TORQUE

Cylinder

Metric,

Bmm

WHEN

HANO

APPLY A THIN GASKET cqNTACTS

SPECIFICATIONS

lb-ft

47.0-57.9

83.2 -90.4

Head

Bolts

section

of

this

manual.)

thread

diameter.

108.5

-144.7

COAT

WHEN

INSTAWNQ,

'lHE

OF

CLEAN

DASE,

TIGHTEN

Kg-m

6.5 -8.0

11.5

15.0 -20.0

OIL

AFIER

IT

AN

-12.5

TD

lH£

RL'ltll

THE

ALTER

AODmDNAL

.

Main

Bearing

Cap

Nut Connecting Flywheel Flywheel Oil Oil

Delivery Nozzle Nozzle

Glow

Bolt -with Bolt -washer

Pan

Drain

Filter

Valve Mounting Holder

Plug

Rod

Plug

Holder

ard

Cap

Nut

separate

(injection

Bolt

Retaining

washers

attached

Nut

pump)

36.2 -39.7

23.1

-25.3

.

Engines & Generators

(or

tighten

83.2 -90.4

94.0-101.3

36.2-43.4

8.0 -9.4 firn11y

28.9

-36.2

10.8

-14.5

43.4 -57.9

10.8

-14.5

by

hand)

5.0-

5.5

3.2-3.5

11.5-12.5

13.0-14.0

5.0-

6.0

1.1

-1.3

4.0-5.0

1.5-

2.0

6.0 • 8.0

1.5-2.0

I

24

TACHOMETER

TACHOMETER/HOUR

The

tachometer/hour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. other the tachometer. The hour volts

alternator charging voltage supplied

on

the back

The

from tachometer input terminal while the the

alternator producing battery charging voltage

volts

The

a

fault

meter.

NOTE:

their battery (s) will stop charging. In such cases, tachometer will stop functioning. mast head amperage

Hour

Check terminals.

1.

Voltage

2.

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

Tachometer

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

1.

Voltage tion

2.

AC output voltage.

3.

Check for

4.

Check electrical connections

Tachometer

1.

Check for proper AC voltage between

2.

3.

Tachometer

1.

With a hand-held tach pulley retaining nut front crankshaft pulley rpm at idle.

of

the

tachometer circuit operates

one of the diodes in t!te alternator

DC.

following are procedures to follow

in

either

of

Many high output

or

running lights, this will result

draw.

meter

Inoperative

for

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

present - meter is defective - repair not present - trace ( +) and (-) electrical con-

Inoperative

for

the proper AC voltage between tachometer input

present - attempt adjusting

access hole. No results, repair

voltage not present - check for proper alternator DC

AC

ground.

minal

to

alternator connection.

Sticking

nal

and (-) terminal.

Check for good ground connection between minal and alternator.

Check that alternator is well grounded to engine block at alternator pivot bolt.

Inaccurate

METER

One circuit operates the

meter

instrum~nt.

on

the two circuits in a tachometer/hour

DC

alternators when fully charged

To

voltage at tach terminal on alternator

from

on

the front

or

using a strobe type tach, read the

hour

meter and the

circuit operates on

to

the(+)

AC

voltage 6-8 volts, fed

and

supplied to the

engine

is running, and

13.0-14.8

when

troubleshooting

overcome

DC

meter

or

tachometer input ter-

of

this,

in

a small

or

to

meter

through calibra-

replace meter.

"tach

inp." termi-

meter(-)

the crankshaft

terminal

the

turn on a

replace.

( +)

DC

to

12

ter-

NOTE:

Current model tachometers use a coarse adjustment dial to set the tachometer to the crankshaft pulley calibrating screw

IDLE

SPEED

&

TACHOMETER

Checking

NOTE:

In a new installation having new instrument panels,

the tachometer may engines rpm. This calibration should be checked in all new installations.

1.

Warm

up Remove cloth and 'place a piece pulley to facilitate use

2. Start and idle

3.

Aim

the light confirm the engine speed. tachometer reading. Adjust the tachometer in the panel using the instrument coarse adjustment to calibrate the . instrument reading to the closest is showing. bring the instrument to the exact reading as the photo_tach.

4. Adjust the idle speed

is

then

used

for

fine tuning.

LIGHT

CALIBRATION

ADJUSTMENT

CHECK

the

idle

speed

not

the engine to normal operating temperature.

any specks on the crankshaft pulley with a clean

the

engine.

of

the

Then

(New

Installation)

always be correctly calibrated to

of

suitable reflecting tape on the

of

a photoelectric. type tachometer.

tachometer onto the reflecting tape

Check

the instrument panel

R.P.M. that the photo tach

use the fine calibration adjustment

if

the engine speed is not within the

JUMPER

TACH

!NP

AG

VOLTAGE

rpms.

The

WIRE

(+)

to

spedfied value. • " i

!"

~

I

'"

;;;

-

;;

Oil

GAUG[

PlttSS.

WA.HR

Tt~P.

G.l.UGt

0~

e

g;

-

"

~

-

TERMINAL(l)

the

to

by

·

2.

Adjust the tachometer using an 2mm Allen head wrench 5/64 (2mm) through the calibration access hole in the rear of

the

tachometer. Zero the tach and bring it to the rpm i

indicated by the strobe or hand tach (verify rpm at idle !

, , . I .

and

at

high speed). Ad1ust the tach as µeeded.

W'

WESTERBEKE--

Engines & Generators

25

"'

'"

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

SHRl

SWJlCll

'"

Pl\[·Sl.1.1\T

©

1

\

WATER

HEATER

WATER

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

trap

HEATER

air.

INSTALLATIONS

the heater to the engine can

··

- ·

~'

./

,/

REMOVE

,,,~

BY-PASS

WHEN WATER

THERE

HEATER

of

IS

NO

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

the system.

~OSECONNECTIONS

/Hoses

/

should.

rise.

continuously from their low. point at the

heater to the engine so that air will rise naturally from the

1

. heater

to

the engine.

then

an

air bleed petcock must

ting

on

the heater for bleeding air while filling the system.

If

trapped air is able to rise to the

be

installed at the higher

he~ter,

fit-

aftt~r

the engine's cooling system is filled with

of

be

done

at

the remote tank and

manif!)ld cap.

The

hose connection from the

REMOTE EXPANSION TANK (

MAINTAIN

air and exhibits

WESTERBEKE)

COOLANT

LEVEL

NOTE:

If

any

portion

engines own

remote

expansion

circuit

to

become

tank

into

the connections single engine's nient remote

fill

point.

the

remote

serves

recove1y

REMOVERETU

BEND.

for

line

up

return.

location

expansion

The plastic coolant recovery tank

expansion tank kit

the same function. Remove and store

tank

of

the

heating circuit rises above

pressure

heater

to

so

if it

cap,

then

tank

(Kit

#024177)

the

highest point.

circuit,

choosing

the

return.

Tee

the

tank's

location and the other back

Install

the

remote

the

coolant level can easily

tank

will

now

has

been

already installed.

a pressurized (aluminum)

must

be

installed

Tee

the

remote

expansion

the

higher

of

the

at

the

heater,

and plumb a

expansion tank

s'erve

as a check and system

is

installed, since this tank

WATER

in a conve-

be

checked.

is

not used when

the

plastic

HEATER

LOCATED

the

in

two

to

the

the The

BELOW

THE

ENGINE

.WATER

HEATER

NOTE:

An air bleed petcock is located on

heat

exchanger.

coolant system

Open this petcock when filling

to

'allow air

Close tightly after all the air

' A

CAUTION:

wear

proper gloves.

Beware

in

the

is

of

LOCATED

exchanger

removed.

the hot

ABOVE

the

engine

THE

ENGINE

engine's

the

engine's

to

escape.

coolant

-

Engines & Generators

26

DESCRIPTION

The

starting

system

and

starter

button.

When

the

starter

button

current

flows

and

energizes energized into to serves flywheel.

To pinion is engine motor

Once

ping contact flow magnetic plw1ger from

the

reach

to

prevent

gear

splined

may

itself.

the

with

of

electricity

its

coil

becomes

coil,

and

closes

the

starter

push

that

drunage

incorporates

to

the

starter

speed

the

started

button

activation

the

battery-to-start

is

:fields

and

is

released,

engagement

motor. starter

to

of

the

its

includes

interrupted

with

the

battery,

on

the

iustrument

the

starter's

fill

electromagnet,

a set of

contacts

At

the

same

pinion

to

mesh

the

starter

motor

an

over-running.(one-way)

annature

rotation

is

the

struier

movement

shaft.

of

released,

solenoid.

cables

to

ceases

the

engine

the

The

the

also

starter

panel

solenoid

which

time,

the

with

when

The

rotation

pinion

but

current

plw1ger

by a coil

starter.

its

rotation.

pulls

the

flywheel.

SOLENOID

STARTER

.

motor,

solenoid,

is

depressed,

coil.

The

pulls

the

plunger

allow

high

current

plunger

the

not

flow

is'

spring,

This

starter

teeth

engiue

clutch

of

the

ceases,

pulled

weakens

As

the

drive

also

on

the

starts,

which

running

starter

stop-

out

of

and

the the

solenoid

gear

·

MOTOR

PN.053295

SOLENOID

IGNITION TERMINAL

TO

CONTROL

PANEL

the

To

test

of

the

small Use a screwdriver, ignition the

solenoid.

If

the starter cranks, the fault

If

the

solenoid

motor

the

ignition

temrinal

tenninal

is

probably

circuit,

don't

to

the

clicks

faulty.

\

locate

studs

and

touch

positive

but nothing

the

is

wired

the

blade,

battery

lies

else

ignition(s)

to

the

to

jl,U11p

connection

with

the

happens,

tenninal

ignition

from

terminal

ignition

the

(it

is

circuit).

that

on

circuit

starter

one

MO

TO

ii

TYPICAL STARTER

REFER DIAGRAM

MOTOR

TO

THE

IN

WIRING

THIS

MANUAL

TROUBLESHOOTING

Prior

to

testing,

make

certain

the

ru1d

that

the

struiing

clean

and

tight

connections To

check

the

never

more

than

the

wires

and

resistance. Using a multimeter,

stud

If

you

on

the

read

Repair

strut

Pay

on

the

wiring,

10

tennmals

or

solenoid

12

volts,

system

particular

engine

block.

try

cranking

seconds

looking

replace

test

the

and

the starter

wiring

attention

at a

any

voltage

the

ships

batteries

co1mections

to

the

starter

time,

then

for

wann

trouble

between

engine

is

faulty.

the

for a few

run

spots

spots.

block

are

at

(terminals)

ground

your

that

the

positive

(grollild).

full

charge

wire

seconds,

hand

along

indicate

terminal

are

SOLENOID

IGNITION TERMINAL

TO

CONTROL

.

PANEL

If

nothing at

Check

the

battery

connections.

A

WARNING:

fly

when

space

is

gasoline.

all

happens the

isolation

It

is

also

jumping

fI:ee

of potentially

switch

possible

There

will

terminals.

solenoid

and

inspect

that

the

solenoid

be

arching

Be

certain·the

explosive

isn't

getting

the

wiring

is

defective.

and

sparks

engine

fumes,

current.

will

especially

Engines & Generators

27

IGNITION

TERMINAL

Test

again

screwdriver

screwdriver would

cause a short.

A

WARNING:

starting screwdriver.

by

jumping blade blade

current

the

firmly

to

touch

There

should

two

large

between

the

solenoid

will be

flawing

terminal

the

be

studs.

Do

o~

starter

arching

thru

STARTER

Hold

the

not

allow

the

casing,

this

as

the

full

the

blade

of

the

MOTOR

SERVICE

Westerbeke serviced

If

replacing certified standards.

TO

1.

Disconnect

2.

If

starter

3.

Label wires

4.

Remove

5.

Remove will

uses a standard

or

rebuilt

the

starter

for

marine

If

in

doubt,

REMOVE

the

necessary,

motor.

and

to

have

remove

disconnect

touch,

the

starter

the

starter

to

be

at

any

motor,

use.

Automotive

contact

FOR

SERVICE

negative

any

tape

over mounting from

turned

ma1ine

starter

motor

make

certain

your

WESTERBEKE

battery

cable.

components

the

wiring

from

the

terminals).

bolts.

the

engine.

to a different

motor

automotive

the

starters

do

to

gain

the

h1

some

angle

which

service

new

not

full

starter.

cases

to

clear

can

be

center.

motor

is

meet

USCG

dealer.

access

to

the

(Do

not

allow

the

starter

obstructions.

If

the

starter

If

the

starter

If

no

arching

NOTE:

Starter

the

pre-engaged engages screwdriver motor

provide

magnetic the

the

without

the

field

solenoid

spins, fails

occurred.

motors

model, starter to

bypass

engaging

power

for

are

bad.

the

to

motor

to

the

solenoid

spin,

the

There

are

either

the

solenoid.also

to

the

solenoid

the

flywheel.

solenoid.

arm

to

motor

is

the

flywheel

move

is

faulty.

is

no

juice

inertia

tjpe

on

such a starter

Turn

Hopefully

even

though

probably

reaching

or

pre-engaged.

moves

an

of

the

engine.

the

starter

it

will

the

faulty.

the

solenoid.

arm

that

Using

will

run

switch

create

contacts

In a

the

on

to

enough

inside

Engines & Generators

28

DC

ELECTRICAL

ALTERNATOR

The

charging system consists

with

a voltage regulator, an engine DC\viring harness, a mounted DC circuit breaker and a,battery with connecting cables.

Because electronic voltage regulator is very compact and internally or

of

on

the back

the use

of

a DC belt driven alternator

of

integrated circuits (IC's), the

of

the alternator.

~

is

mounted

SYSTEM

1.

Start the engine.

2. After the engine has run for a starting battery voltage at multimeter set on DC volts.

a.

If

the voltage

tor is working; omit Steps 3 to "Checking the Service Battery"

b.

If

the voltage remains around exists with either the alternator or continue with Steps 3 through

is

the

increasing

few

minutes,

battery

terminals

toward

14

tlu-ough 8 and

on

12

volts, a

the

8.

measure

volts,

the

go

the

charging

using

alterna-

directly

page.

circuit;

the

a

#10

RED

,AT

STARTER

51A

ALTERNATOR

Refer

to

the

this

manual

and

their

wiring

112

BLACK

the

alternator

or

the

staJ.ting

TO

AT

STARTER

can

be~ome

has

or

with the alternator.

voltage regulator

battery is not discharged

If

the-alternator is charging the

cooled

if

a problem

very down.

If

is

faulty,

it

is

GROUND

ALTERNATOR

A

WARNING:

hot.

Do.not

Use

this

exists

with detennined 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

along

with the service battery.

starting battery but not the service battery, the problem the

service battery's charging circuit and not with the altema·

tor.

Testing

TROUBLESHOOTING

A failed alternator

touch

until

troubleshooting section to detennine

the charging circuit

batte1ies

the

Alternator

so

BATTERY

CONNECTOR

WIRING

for

the

alternator

connections.

is

in

MULTIMETER-~e

(SHOWN)

DIAGRAMS

IN

models

TESTING

THE

STARTING BATTERY/ALTERNATOR (ENGINE

3.

Turn

Ensure that the battery connections are tight and

A

charging switch

4.

If

a battery selector switch

ensure that it is on the correct

5.

Tum

6.

Check the battery voltage. tion, the reading should be

RUNNING)

off the engine. Inspect

CAUTION:

circuit,

when

tlie

' .

on

the ignition switch, but

Lenninals

To

avoid

never

engine

.

-::-

all

clean.

damage

shut

oft

is

running!

is

in

setting.

If

the battery

12

to

mm

COM

GROUND

wiring,

and

the

engine

to

the

engine

the charging

do

not start

is

13

volts.

connections.

ground

battery

circuit,

the

engine.

in

good

condi-

A

CAUTION:

that

everyone

sheaves

A

DC applications. isolate before made

and

WARNING:

and

AC DC

performing

without'a

Before

is

clear

belts

circuits

Always

and

AC

proper

starting

of

moving

during

test

procedures.

When

testing

are

often

mixed

disconnect a shore converters, DC

testing.

and

No

knowledge

the

parts!

with a multimeter:

AC

engine

Keep

together

shut

down

tests

of

AC

circuits.

make

away

in

marine

power

cord,

the

should.be

certain

from

TESTING

engine

ALTERNATOR

(IGNITION

Engines & Generators

29

THE

VOLTAGE

ON -ENGINE

OFF)

-

'GROUND

7.

Now

check

minal

(B+)

the

alternator

tor

is

in

the

neither

of.the

between

connections -look

the

voltage

and

ground.

will

be

circuit

above

alternator

between

If

the circuit

the

same

as

the

alternator voltage

is

true,

a problem

and

the

battery.

for

an

opening

DC

ELECTRICAL

the alternator output

is

good,

the

voltage

the

battery,

in

MULTIMETER

will exists Check the

charging

or

be

in

all

if

an

zero.

the

circuit

the

cra:5]

ter-

isola-

If

circuit.

at

SYSTEM

Checking

Check the voltage of the service battery. have a voltage between running. If charging circuit. Troubleshoot the service circuit isolator, battery switch,

the

Service

not,

there is a problem

by

checking the wiring

Battery

13

and

14

volts

in

and

the battery itself.

the

connections,

TI:ris

when

service

battery

the

engine

battery

charging

the

should

is

solenoid,

TESTING BATTERY/ALTERNATOR

(ENGINE

8.

Start

alternator

The should is service

NOTE:

voltmeter to ensure at the

tery voltage

Ij

wiring

THE

STARTING

RUNNING}

the

engine

again.

oµtput

and

voltage

over-

12

reading for a properly operating alternator

be

between

or

under-charging,

facility.

Before removing the alternator

EXC

volts is not present

and

13.5

tha.t

tenninal if the previous test showed only bat-

at

the B output terminal.

look

for

·

Check the voltage between the

ground.

arid

14.5

volts.

If

your alternator

have it repaired at a reliable

for

repair, use a

12 volts

at

breaks and

the

DC

excitation

EXC

tennina~

poor

connections. •

trace the

is

present

MULTIMETER

GROUND

A

CAUTION:

diodes, when

do

perfonnlng

·e

not

use a high

00J

COM

To

avoid

tests

damaging

voltage

on

the

alternator

TESTING BATTERY

THE

(ENGINE

the

alternator

tester

(I.e. a megger} charging

SERVICE

RUNNING)

circuit.

12

VOLT

DC

The

engine

shown

on diagrams electrical

A

CAUTION:

circuit, the

engine however,. engine's

CONTROL

has

a

12

the

wiring

when

troubleshooting or when servicing the

system.

To

never

shut

Is

running.

to

avoid

electrical circuit. ·

CIRCUIT

volt

DC electrical control circuit that

diagrams that

avoid

damage

off

the Shut

electrical

engine

off

the

shorts

follow.

to

battery switch

engine

BAnERY

The

recommended

starting

Cranking

12

volt

Amps

"dedicated"

DC

control

(CCA) rated.

battery used

circuit should be

the

when

Refer

battery

working

for

is

to

these

DC

charging

while

battery switch,

on

the

engine's

800..1000

Cold

Engines & Generators

Battery

Review the manufacturer's recommendations

establish a systematic maintenance schedule starting batteries

Care

and

house batteries.

D Monitor your voltmeter for proper charging

operation. ·

D Check the electrolyte level

hydrometer.

D

Use

only

distilled water

level.

to

and

bring

D Make certain that battery cable connections

tight

to

the battery posts

D .l(eep your batteries clean

A

WARNIN.G:

cause

severe

protective

Sulfuric

bums

gear.

on

acid

skin

(and

and

to

free

In

damage

30

and

then

for

your

engine's

during

engine

specific gravity

~lecb:olytes

your engine).

of corrosion.

lead

batteries

clothing.

with

to a proper

are

clean

can

Wear

a

and

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preheat solenoid I terminal.

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ENGINE

TROUBLESHOOTING

The following troubleshooting table describes certain problems relating to engine service, the probable causes

of

these problems,

and the reconunendations to overcome these problems.

No

panel

Indications;

not

working

PREHEAT

START engagement.

Engine start.

Engine

Battery

(key

button

cranks,

can't

be

runs

down.

not

charging

Problem

fuel switch is

depressed).

is

depressed,

but

does

stopped.

pump

is

ON

not

and

no

is

starter

1.

Battery 20-amp

2.

3.

Loose

Connection

1.

(Hydraulic

Gear

2.

Faulty

3.

Faulty

4.

5.

Loose

Low

6.

1.

Faulty

Preheat

2.

Low

3.

Disconnected

1.

Oil

pressure

1.

High

2.

Low

3.

Poor

4.

DC

alternator

5.

(tachometer DC

alternator

1.

2.

Alternator

Probable

switch

not

circuit

breaker

connections

to

solenoid

Transmission)

shift

not

in

switch. solenoid.

battery

connections.

battery.

fueling

system.

solenoid

battery

power.

fuel

switch.

resistance

battery

connections.

not

drive.

Cause

on.

tripped.

between

faulty.

neutral.

faulty.

shut-off

leak

to

ground.

leak.

charging

operating).

NOTE:

The engines electrical system is protected by a 20 ampere manual reset circuit breaker located on a bracket. The preheat solenoid

is

mounted on the same bracket.

Verification/Remedy

1.

Check

switch

and/or

battery

connections.

2.

Reset

breaker;

if

breaker

trips

again,

shorts

to

and

secure

(see

NEUTRAL

at

the

Bleed filters

start

lever.

lights

pressure

(0 -.25

Remove

rise

battery

belt

tension,

of

the

DC

output

terminal.

check

ground.

with

solenoid

air

from

and

bleed

batteries.

Pull

lever

are

activated

switch.

amp)

connections

to

locate

for

loose

test

alternator

should

with

voltmeter.

the

panel

cable.

circuit

3.

Check

1.

2.

Gear

WARNER

3.

Check

4.

Check terminal.

5.

Check

6.

Check

1.

Check

1a.

Check

1b.

Fuel fuel

2.

Check

3.

Switch

3a.

Replace

1.

Check

the

1.

Observe is

2.

Check lines. after

3.

Check

4.

Check corrosion

5.

Check

SERVICE

1.

Perform

2.

Check for volts

and

check

the

plug

connection

connection.

shift

must

TRANSMISSIONS)

switch

with

that

12

volts

battery

connections.

battery

charge

that

fuel

valves

for

air

in

filters

clogged.

system.

solenoid.

to

combine

batteries.

connection

fuel.

if

gauges

not

running.

Test

wiring.

Insert

(Do

not

start

short

is

located.

all

wires

cable

connections

connections,

MANUAL.

DC

voltage

drive

belt

loose

connections.

are

present

circuit

be

in

neutral

ohmmeter.

are

present

state.

are

fuel

system.

Replace

house

at

shut-off

and

panel

the

sensitive

engine.)

for

temperature

check

tension;

Check

at

the

for

open.

and

oil

at

alternator

Exe.

preheat

solenoid

tie

wrap.

SWITCH

activation

fuel

system.

air

from

back

to

close

when

meter

in

and

the

fault.

connections,

alternator.

turn

freely.

Ensure

under

off

engine

battery

replace

See

Check

12

lw,WESTERBEKE

~nalnss

& Generators

33

Engine

slows

Engine

overheats/alarm

.

Engine

alarm

Engine

(Low

or

Exhaust

alarm

High

smoke

Problem

and

stops.

sound

pulsates.

sounds

continuously.

Volumn)

problems

sounds.

ENGINE

Probable

1.

Fuel

lift

pump

failure.

Oil

switche

2.

3.

4.

5.

1.

2.

1.

2.

1.

2.

3.

or Fuel 20

Water

Raw Coolant

Loss

Oil Faulty

Blue

White

Black

and/or

disconnected.

starvation.

Amp

circuit

breaker

in

fuel.

water

not

circulating.

not

circulating.

of

oil.

pressure

switch.

Resistor.

smoke.

TROUBLESHOOTING

Cause

wiring

tripping.

loose

1.

Fuel pump

2.

Inspect Inspect

3.

Check

4.

Check Ensure cause

5.

Pump bleed

1.

Raw

2.

Obstruction

2a.

Thermostat -remove

Replace

2b.

Loss

for

2c.

Broken

2d.

Air bleed

1.

Check oil

2.

Replace

1.

Resistor

1.

Incorrect

1a.

Crankcase through

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel insufficient exhaust

3b.

Improperly

3c.

Lack ventilation.

3d.

Overload.

Verification/Remedy

lift

pump

should

with

spare.

wiring

for

switche fuel for

breaker

tripping.

water

fuel

water

of

coolant -check

leaks.

or

leak

in

air.

dipstick,

drain

is

injector

burn

of

short

for

proper

supply,

fuel

high

DC

amperage

is

not

from

fuel

system.

pump

failure.

at

raw

water

thermostat.

loose

belts -tighten/replace.

system;

run

Add

coolant

look

connection.

pressure

Preheat

of

engine

is

overfilled

exhaust).

cold.

or

incorrect

of

fuel.

air

for

proper

check

timed

injectors

for

hose oil

off.

grade

the

running

grade incomplete

system;

air -check

make a distinct

circuits

operation.

valves,

overly

tank(s);

Check

intake

and

test

hoses,

engine

as

needed.

oil

leaks

switch. solenoid 1 terminal

oil.

with

engine

injector

due

to

combustion

air

intake).

or

air

intake

ticking

and

loose

connections.

fuel

lift

pump.

draw

during

sensitive

change

impeller -replace. or

in

and

high

valves,

and

operation.

to

heat

filters

raw

water

hot

water.

hose

clamps,

open

the

pressure

at

oil

filter

and

(1 K ohm

oil

(oil

is

timing.

back-pressure

(check

or

poor

air

filter.

Check

sound.

Replace

which

would

and

filter.

drain

plug,

cap

at

value).

blowing

out

in

exhaust

for

restrictions

compression.

for

proper

etc.

to

or

in

TROUBLESHOOTING

If

the gauge reading is other than what is normally indicated

by the gauge when the instmment panel is energized, the first

DC

step is to check for 12.volts and the Negative (B-) terminals

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

1.

Disconnect the sender wire

gauge reads zero, which

situation.

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

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

between the ignition (B+)

of

the gauge.

at

the gauge and see

is

the normal reading for this

See

COOLANT

if

the gauge reads

TEMPERATURE

if

the

lw,WESTEllBEKE

Enalnss

34

AND

OIL

If

both

of

the above gauge tests are positive, the gauge is

undoubtedly

PRESSURE

OK

and the problem lies either with the

GAUGES

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

If

either

of

the above gauge tests are negative, the gauge is

be

probably defective and should Assuming the gauge is

OK, check the conductor from the

replaced.

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

/,.

Generators

ENGINE

ADJUSTMENTS

ADJUSTING

1.

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

2.

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

3. Tighten the locknut.

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

remains as set.

NOTE:

tachometer a

mechanical

crankshaft.

STOP

CONTROL

THE

IDLE

SPEED

Should

the

engine

rpm

readings

as

shown

or strobe-type tachometer at

See

TACHOMETER.

ENGINE

STOP

CABLE

POSfTION STOP

.

ENGINE

CABLE

CONTROL

DOWN.

be

in

question, verify

at

the instrument panel with

the

THE ADJUSTMENT

SET.

ADJUSTMENT

SO

THAT

WILL

THE

SHUT

THE

on

the

engine

HIGH

.

the

SPEED

rs

FACTORY

3/8'

TO

1/2'

DEFLECTION

Adjusting

1.

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

2. With the belt loose, inspect for wear, cracks and frayed edges.

3. Pivot the alternator or

4. Tighten the base mounting bolt and the adjusting strap

bolt.· ·

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

recheck the belt tensions.

~WARNING:

drive

Belt

Tension

on

the base mouhting bolt to the left

right as required, to loosen

Never

attempt

belt's

tension

l(lhi/e

the

or

tighten.

to

check

engine

or

adjust

is

.in

operation.

the

RECOMMENDED

Model

35BffHREE

38B/FOUR

43B/FOUR

NOTE:

What ever style propeller

load

the

engine

RPM

of

3600 + 0 -

in

forward gear for

RPM

RANGE

Idle

RPM

800-1000

750-

900

750-

900 2500 - 3000 3500 - 3600

it MUST allow

100 the

Cruise

25002500-

is

being

the

engine

at full open tlirottle while underway

correct propeller load on then

engine.

Max.

3500-

To

properly

RPM

its

3600

rated

RPM

3000 3500 - 3600 3000

used.

to

Peach

lwlWEBTERBEKS

) Engines &

BELT

INSPECTION/MAINTENANCE

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

Drive Belts under MAINTENANCE

(see

Drive belts must

will not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pull the alternator out alternator to tension can also cause rapid wear service life presence in high operating temperatures and tachometer variations.

The drive belt is properly adjusted no less than 3/8 inch (lOmm) and no more than

(12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span belt. A spare belt

of

be

wear

out prematurely. Excessive drive belt

of

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

oil on the belt can cause belt slipping, resulting

or

G~n.,ratOi'S

35

of

the drive belts

of

your engine

SCHEDULE).

properly .tensioned. Loose drive belts

of

alignment and/or cause the

of

the .belt and reduce the

if

the belt can be deflected

l/2

inch

of

belts should always

be

carried on board.

·

the

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust-

ments be performed by a competent engine mechanic.

below is provided to assist the mechanic.

Torquing

Tighten the cylinder head bolts according to the sequence

shown. Make Before applying the specified torque to the bolt, loosen it 1/4 procedure according to the numbered sequence shown.

NOTE:

Cylinder

sure the engine is cold when this is done.

112

of

a turn and then apply the torque. Follow this

MJO

Head Bolts require a 14mm socket.

M12 Head Bolts require a 17mm socket.

~Qad

Bolts

(W

358

Three

Engine

ADJUSTMENTS

The information

#4, #5, #6, #7, #8, #9, #10 and

Bolts between 83.2 - 90.4 lb-ft (11.5

Bolts #1, #2, and #3 are tightened between (6.5

- 8.0 kg-m) wet.

Q<;

ENGINE

•

FRONT

02

#11

- 12.5 kg-m) wet.

0

7 4

0

01

are tightened

47.~

- 57.8 lb-ft

0

5

6

0

03

0

11

8

0

VALVE

358

Adjust

are engine, (1-3-2). Tightening specified pages).

1. Pull off the

2. Adjust the valve clearances at

3. Align the timing mark

4. Next the No.3 cylinder, turn the crankshaft clockwise

CLEARANCE

THREE

adjusted

take

for each stroke. Remember the engines firing order is 1-3-2. You may find that tuning the engine's crankshaft is more

easily accomplished when the engine's glow plugs are

removed before the crankshaft is rotated.

mark pulley indicated for cylinder #1 (the one nest to the three injection timing marks). In this position, the No.I cylinder is at its top

compression stroke. Check both the intake and exhaust

valve specified clearance, adjust by means screws. Remember to align the timing marks properly, not the valve may on the position valves for this cylinder

240° so the TDC mark for the No.3 cylinder crankshaft pulley is approximately at the position shown in the illustration. Adjust the intake and exhaust valves for cylinder No.3. Be sure to check the valves for this cylinder as they both should

5. Last is 240° to position the approximately at the positfon shown in the illustration: Adjust the intake and exhaust valves for cylinder No.2. Be sure to check the valves for this cylinder as should

Adjust (0.25

mm)

valve stem.

ENGINE

the

valve clearance

by

torque

off

the rocker cover bolts and the rocker cover.

cylinder when they are on their compression

clearances for this cylinder.

~e

No.2 cylinder, turn the crankshaft clockwise

be

closed.

each

valve's

feeler gauge between

ADJUSTMENT

when

the

engine is cold. Valves

the

cylinder

before

air breather pipe from the rocker cover and

be

of

the cam lobe.

clearance

in

the

firing

order

of

the

cylinder

adjusting

TDC

on

the gear case with the timing

Timing mark while dead center

pushed

me

up

as

they both should be closed.

be

closed.

mark on the crankshaft pulley

by

head

bolts to

the

valves (see previous

(Top Dead Center)

If

the· valves have no

of

the adjusting

by the piston, depending

Be

sure to check the

on

the front

theyboth

inserting

the

rocker

a·

0.010

arm

and

in

the

on

the

if

its

TDC

MARK

CYLINDER.

NO

VALVE

.2

CLEARANCE

ADJUSTMENT

l-w-IWEB7ERBEKE

l

EnalntJS

&

Generators

36.·

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. below is provided to assist the mechanic.

ADJUSTMENTS

The

information

Torauing

W

388

Tighten the cylinder head bolts according to the sequence

·

shown in the illustration. Make sure the engine is cold when this loosen it

: this procedure according

Bolts between 83.2

Bolts (6.5 -8.0

VALVE

W

388

Adjust

Tightening before

1.

Pull

2.

for

3.

4. After adjusting the valves for cylinder No.I, rotate the

5.

6.

Cylinder

FOUR

is

done. Before applying the specified torgue to the bolt,

1/4

to

#5,

#6, #7, #8,

- 90.4 lb-ft (11.5 - 12.5 kg-m)wet.

#1, #2, #3

kg-m) wet.

CLEARANCE FOUR

the

valve

the

adjusting

off the air breather pipe from the rocker cover and

take off the rocker cover bolts and the rocker cover Adjust the valve clearances at TDC

each cylinder when they are on their compression stroke. Remember the engines firing order is 1-3-4-2. The engine's valves must be adjusted in this order while the valves are closed. crankshaft engine's glow plugs are removed before the crankshaft is rotated.

Rotate the engine in the normal direction of rotation placing the stroke. The TDC mark on the crankshaft pulley should be in

line with the pointer on the front and Now No.1.

front crankshaft pulley clockwise on

shown for cylinder No.3. Now adjust the intake and

exhaust valves for cylinder No.3. Rotate the crankshaft pulley clockwise another 180° and

adjust the valve clearances for the intake and exhaust valves for cylinder No.4. '

Rotate the crankshaft pulley clockwise another 180° and adjust the valve clearances for the intake and exhaust valves for cylinder No.2.

is

the valves for the No.1 cylinder should be closed.

adjust the intake and exhaust valves for cylinder

the pulley is positioned approximately in the position

Head

Bolts

Engine

1/,2

·and

and W 428

of a tum and then apply the torque. follow

to

the numbered sequence

#11,

#12. #13 and #14 are tightened

#4 are tightened between 47.0 - 57.8 lb-ft

FOUR

.

engine

Shown.

ADJUSTMENT

AND

W

428

FOUR

ENGINE

clearance when the engine

cylinder head bolts

the

valves.

You

may find that tuning the engine's

more easily accomplished when the

No.1

cylinder at the top

to

180° so the TDC mark

is

cold.

the specified

(Top

Dead Center)

of

its compression

of

the gear case cover

torque

..

ENGINE

•

FRONT

ROTATION

TDC POSITION CYLINDERS

N0.2 & N0.3

\

MARK

3

0

FOR

VALVE

0

7·

9

0

TDC CYLINDERS

CLEARANCE

0

5

6

0

1

:o

MARK

POSITION

N0.1 & N0.4

ADJUSTMENT

(j

10

8

O'

2

0

FOR

0

12,.

14

0

4

0

Adjust (0.25 valve

each

valve's clearance by inserting a 0.010 in

mm)

feeler

gauge

between the rocker arm

stem.

and

the

Engines & Generators

37

HBW~Zf

MARINE

DESCRIPTION

The information below is specific to the the

TRANSMISSION

applies

to

all models.

CONNECTION

HBW recommend a flexible connection between the

transmission gearbox and the propeller shaft

flexibly mounted, in order to compensate for·angular

ddiection:;.

bearing tiken by specified under SPECTFICATIONS However, the output shaft should additional loads. Special care should torsional vibration. certain to observe the manufacturers instructions.

Even with the engine solidly mounted, the use coupling or

gearbox bearings caused by hull distortions, especially in wooden boats or where the distance between transmission output

The installation

is

not required, since the propeller tlu·ust will be

tl1e

transmission bearing, provided the value

"DRIVESAVER" will reduce stress in the

flange and stem gland is less than about

TROUBLESHOOTING

OF

GEAR

BOX

of

a special propeller tlu-ust

When

using a universal joint shaft, make

ZF

WITH

PROPELLER

is

not exceeded.

be

protected from

be

taken to prevent

Transmissions,

SECTION

if

the engine

of

flexible

SOOmrn.

ZF

15M

TRANSMISSIONS

NOTE:

When installing the transmission, make certain that shifting is not impeded Bowden cable sheaves, too small a bending radius, etc.

support threaded holes located above the shift cover on top gear housing. Refer to the WESTERBEKE parts

is

CONTROL

The transm.ission is suitable for single lever remote Upon loosening the retaining screw, the actuating lever be moved to any position required for the control elements

(cable or rod linkage). Make ce1tain that the shift lever not contact the actuating lever cover plate: the minimum distance between lever and cover should be

The control cable or rod should be arranged

the actuating shift lever when in the neutral position. The

neutral position

should coincide with the neutral position of this lever.

The shifting travel, as measured at the pivot point of

actuating lever, between the neutral position and end

positions A

30mm

A greater amount detrimental and is recommended. However, if the lever travel

is

which, in tum, would mean premature wear, excessive heat

generation and clutch plate failure. This would be indicated by slow clutch engagement or no engagement

NOTE

Check

or

for

shift control cable connections, use the

CABLES

and

for the inner pivot point.

shorter, proper clutch engagement might

for

by

rod linkage,

of

the operating lever on the control console

B should

of

shift lever travel

proper lever travel at least each season.

FORWARD

restricted movability

by

unsuitably positioned guide

be

at least

35mm

is

in

NEUTRAL

N

A

of

In order

list.

0.5mm.

at

right

for the outer

no

way

at

the

to

mount a

two

of

the

control.

can

does

angle

the

be

impeded

all.

REVERSE

B

to

and

MAXIMUM INCLINATION

A

CAUTION:

the

actuating

shift

lever

this

mechanism

transmission

The

lever

travel

is

warranty

position

is

factory-adjusted

from..

in

any

neutral

way

will

be

of

the

position A and tampered

rioid.

mechanism

to

ensure

B.

with,

the

behind

equal

If

SHIFT

--

LEVER

05mm

MINIMUM

0

COVER

1=

DISTANCE

HBW-ZF

MARINE

TRANSMISSIONS

INITIAL

All with reasons

Fill

(DEXRON to

just insert the

into not Check also hoses,

OPERATION

HBW

marine transmissions are test-run on a test stand

the

engine at

the

gearbox with Automatic Transmission Fluid

the

index mark on the dipstick.

the

case after

forget

the

for

leaks

make

and

the

factory prior

fluid

is

drained before shipment.

II or DEXRON III). The

dipstick,, sealing ring under the hexhead

a visual inspection of the coupling, oil cooler and

shift cables.

do

the

fluid

and

change the

DIPSTICK

not screw it

level is checked and tighten. Do

to

To

fluid

NOTE:

.

opening

CHECKING

'FLUID

FLJJID

f!lm~1

FLUID

ORAi~~

I

FLUID

CHANGE

Change operation, year or when

Removing

Push the

allows, from drain washer. the recheck

DRAIN

NOTE

drain plug sealing washer. The drain this sealing washer.

the

fluid

for

the

first

time after about

then every 250 operating hours or at least once a

you

change engine oil.

the

fluid

a suction

bottom of

the

into

used

PLUG

pump

hose down through the dipstick hole

the

housing and suck out the

use

the transmission drain). Remove the drain plug

bottom of

a container, then reinstall the plug with

Wipe

fluid.

the

TORQUE

the

transmission and allow

down

the

transmission and properly dispose of

After running the engine, shut down

fluid

level.

20 -25

fl/lbs

: When changing the fluid, take care

delivery. For safety

fluid

level should be

check the

in.

after the

Keep

LEVEL

plug

fluid

level,

Screw the dipstick

of

the

dipstick.

first

25

hours,

vent

cleqr.

iTRANSMISSION

OPERATING

.

25

hours

fluid.

(If

space

the

fluid

its

sealing

and

nQt

to lose the

will leak without

of

to

up

to

OPERATING

The maximum permissible 230°

{110°).

time.

Il

CAUTION:

too

high,

LOCKING

Locking required:

tion of travel for this purpose. Never put the gear shift position corresponding to the direction

WHEN

Rotation of the propeller without load, such being sailed, being towed, or anchored in a operation ing

the

mission

DAILY

D Check the transmission

D Visually check the gear shift linkage

D Start the engine in neutral, allowing a

idle to warm the

D Shift into

NOTE

: Too low

from the transmission

the idle

For additional information refer Transmission Section:

AND

TRANSMISSION TROUBLESHOOTING.

General

Gear

Nole: of

gear

Only a few

Lubricating Propeller

Direction

TEMPERATURE

ATF

temperature should not

This temperature can only be reached for a

If

the

transmission

stop

the

engine

immediately

THE

PROPELLER

of

the propeller shaft by

use

the gear shift lever position opposite your

UNDER

battery), will have

SAIL

OR

BEING

of

the engine with the propeller stopped (for

no

detrimental effects on

fluid

and

an

additional brake

of

travel of the

TOWED

OPERATION

fluid.

and

fluid.

gear.

an

idle

speed

will produce a chattering noise

gear

and

damper plate. In such cases

speed

should

be increased

to

the following text

SHAFT

ZF

TRANSMISSIONS

ratio

(optional)

There

are a variety

ratios

available.

are

listed.

Fluid

Shaft

of

Rotation

COUPLINGS, MAINTENANCE

SPECIFICATIONS

(ZF

Standard

hardened servo-operated

ZF

15MA

ZF

10MA

ZF

12MA

ZF

15MIV

ATF

-

Right-hand

listed

Transmission)

helical

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

(2.13:1

Type A or

rotation

gears,

multiple

or

Dexron -II

temperature

check

as

when

river,

as

well

the

transmission.

few

minutes

Case-

with

a

disc

clutch.

2.63:1)

2.72:1) or

Ill

for

above

models

the

is

in

boat.

the

in

exceed short

is

not

direc-

the

boat

as chargtrans-

at

this

is

Il

WARNING:

engine

is

dipstick

Never

running.

hole.

This

pull

Hot

fluid

could

out

the

will

cause

splash

severe

dipstick

from

burns.

while

the

lw/WEST'ERBEKS

Em1lnes & Generators

39

HBW-ZF

MARINE

TRANSMISSIONS

OPERATING

A

CAUTION:

too

high,

transmission

Normal operating temperature should be in the range

A maximum temperature of 266° F

reached

Make certain there to

provide good ventilation and cooling.

TRANSMISSION

Coolers are standard equipment for the ZF

ZF 15M, ZF 15MA,

The cooler is a separate part

prevents any possibilities of coolant diluting the transmission fluid.

However, the continued

will,

in

leaks.

A transmission cooler may last ten years or more but,

some circumstances, depending on operating hours, tropical

waters, maintenance, etc. it might only last half that

WESTERBEKE

TEMPERATURE

If

the

transmission

stop

the

engine

immediately

fluid.

of

122° F (50°

for

a short

time. is

enough space around the transmission

COOLER

ZF

15MIV,

time, erode the inside

reconunends having a spare cooler

fluid

temperature

and

check

of

the transmission

C)

to

(130°

C)

and the ZF 25M.

of

the transmission which

flow

of

coolant thru the cooler

of

the cooler causing external ·

fluid

212° F (100°

may

be.

lOM,

ZF

is

the

C).

only

12M,

in

time.

aboard.

MAINTENANCE

Transmission maintenance is minimal.

housing clean, check the fluid level routine, and change

Periodically inspect the transmission and corrosion. Make certain the air vent checking the fluid level look

(fluid will appear

Lay-up/Wi~terize

Storage requires special care. Follow these

D Drain water

with a proper mixture of antifreeze

NOTE:

This

engine

raw

D Clean up the transmission

(use heat resistant paint).

0 Fill the transmission with

prevent internal corrosion (extended storage months or

the

fluid

as

strawberry cream).

from

the

transmission

operation

water

more).

will normally

cooling

every 300 operating

for

system

and

Dextron

0 Loosen attaching hardware from the

flange and propeller shaft coupling removing the boat from the and spray

with

lubricant.

D Inspect the gear shift cable, linkage,

Look for corrosion of the end

the conduit, and bending of the actuator all

moving parts.

Keep

as

part of your regular

and

signs of water contamination

oil

coolant.

occur

is

properly

touch

III

flange

water.

Separate the

fittir,igs,

the

exterior

hours.

the cooler

is

clear and

procedures:

cooler

and

when

winterized.

up

unpainted

ATF

fluid

only,

ti.:ansmission

before

and

attachments.

cracks

qr

rods.

Lubricate

for

leaks

when

replace

the

areas

to

twelve

output

flanges

cuts

in

.PERIODICALLY

EROSION

AND

INSPECT

LEAKAGE

FOR

NOTE:

If

the

transmission

(twelve

fluid to prevent

before putting

months

is

or

more),

it

internal

the

corrosion.

engine

back

ZF

MARJNE

ZF Industries

Marine 3131SW42nd Street

Fort Lauderdale,

Tel.:

(954) 581-4040

Fax: (954) 581-4077

Website:

to

be

stored

for a long

should

be

topped

off

with

Reduce

into

service

the

fluid

GEAR

US

Headquarters

FL

33312

WWW.ZF-MARINE.COM

time

level

Engines & Generators

40

HBW • ZF

TRANSMISSION

TROUBLESHOOTING

CONTROL

The majority improper clutch engagement (manual transmissions)

CABLES

of

transmission difficulties arise as a result

of

or problems with control cables (hydraulic transmissions) rather than from problems with the transmission itself.

If

you experience operating problems with the transmission,

shut the engine down.

First

che~k

the transmission-fluid ·

level, then have a helper move the cockpit shift lever through

the full range - from neutral to full forward, back to neu-

tral, into full reverse, and back to neutral observe the actuating lever

on

the transmission.

- while you

If

the remote is stiff to operate, break the cable loose at the transmission and

try again.

If

it is still stiff, check the cable for kinks or

excessively tight bends, and check any linkage for binding.

Problem

Transmission Fails

to

move

Transmission fails

to

propel

Delay

of

gear

only

after

an

increase

Transmission

Chattering mainly

Boat

Oil

transmission

at

low

fails

to

Leakage.

attain

gears

cannot

into

gear.

shifts

into

the

engagement

noise

engine

gear,

boat.

in

speed.

becomes

noise,

speed.

specified

be

shifted.

but

or

engages

louder.

max.

speed.

1.

Actuating

2.

Shifting unattached.

3.

Shift

1.

Output

2.

Propeller

Output

3.

Output propeller

1.

Actuating equal

2.

Actuating

3.

1.

Damage to

wear

ment Beginning

2.

mission without transmission,

The

engine

1.

vibrations a

"chattering"

1.

Operating

2.

Operating

1.

Corrosion Damage

Misalignment

2.

Probable

lever

is

cable

is

Cable

lever

is

binding

coupling

shaft

is

coupling

shaft

are

lever

travel

to

N

to

A.

lever

travel

lever

is

starting

or

fatigue,

between

engine

damage

due

to

torsional

fluid,

overload,

or

propeller

in

the

noise

temperature without

at

radial

sealing

of

Cause

loose.

broken,

radius

against

is

not

turning.

not

turning.

is

turning.

and

turning.

N

is

binding

on

flexible

possibly

and

of

bearings

excessive

drive

unit

in

cooling.

sealing

ring. output

bent

or

is

too

severe.

cover

to

B

not

.

insufficient.

against

coupling

due

to

transmission.

in

vibrations,

wrong

alignment

engine

generates

which

the

transmission.

is

high.

ring

and

flanges.

A new cable and perhaps a new linkage mechanism may be needed. While the cable is loose, shift the transmission in and out

of

gear using the lever

on

the side

of

the transmission to

make sure there's no binding inside the case.

If

the transmission passes these tests, crank the engine and

it

have a helper put the propeller shaft; needs professional attention. thrust, check the shaft or, it

isn't

stuck in the

NOTE:

If

you suspect a major problem in your transmission,

immediately contact your WESTERBEKE dealer

in forward and reverse while you observe

if

to

you

see

the shaft

you

have

"no

isn't

turning, the transmission

If

it

still

does tum

have

a propeller on the end

but

a folding or feathering propeller, that

pitch" position.

there's no

or

an

of

authorized marine transmission facility.

Verification/Remedy

1.

Tighten

damping

bolt

on

actuating

lever.

2.

Check

the

cable,

reattach

or

replace.

.

plate.

cover

misalign-

trans-

running

output.

torsional

produces

shaft.

plate.

due

of

3.

Detach Clearance

1.

Transmission

2.

The

coupling

on

the

propeller

pins

and

3.

Inspect A

folding

propeller

1.

Adjust

See

ACTUATING

2.

Check

shift

DIAGRAM.

3.

Check

clearance,

1.

Check

alignment, inspect engine.

2.

Transmission

1.

Mount a flexible

between

a

higher

2.

Inspect

transmission.

1.

Wrong

2.

Check

1.

Transmission

2.

Check

the

shift

cable

should

needs

bolts

shaft.

coupling

the

propeller;

propeller

may

cover

plate

lever

the

damper

Replace

it

needs

coupling

the

engine

stiffness

the

damper

type

of

fluid.

cooler.

Inspect

needs

alignment.

and

operate

be

0.02

in

(0.5mm).

professional

are

sheared

Tighten

bolts

it

may

be

in

"no

until

the

LEVER

cable

length.

adjust

inspect

plate

necessary.

professional

and

factor

plate

Replace

Use

coolant

professional

Must

attention.

or

replace

as

necessary.

may

be

!llissing

be

jammed. A variable pitch"

lever

is

TEXT

AND

See

if

necessary.

flexible

coupling.

between

with

another transmission; a coupling might

be

between

if

necessary.

ATF

Dextron

hoses

be

within

the

lever

by

the

coupling

set

screws,

or

damaged.

position.

exact

mid-position.

DIAGRAM.

ACTUATING

It

the

attention.

sufficient.

the

attention.

0.003

noise

transmission

stiffness

engine

Ill,

check

and

coolant

in

(0.08mm).

hand.

is

slipping

pitch

LEVER

factor

with

and

the

fluid

flow.

keys,

persists,

and

the

level.

Engine.s

41

& Generators

JS

AND

BW

DESCRIPTION

The

transmission's gear ratio

transmission turns a righthand propeller when engaged in

forward

harde.ned

The system. with each transmission. internal preservative, providing reliable protection against corrosion for

The transmission on exclusively. transmission. may

gear.

The JS/BW transmits its power with case-

helical

gears

reversing process

For safety reasons,

lubricating for shipiperit. Before leaving

transmission is thoroughly tested with oil in the

This testing, among other things, provides

parts with a coating of oil. This oil acts

at

least one year if

transmission

the

dipstick with

have

is

up

to

Multigrade

DO

an

API

an

or near the

SAE

NOT mix grades of

specification of

is

2.47 to

and in reverse, an intermediate

is

carried out by a servo double disc

the

transmission

the

transmission is properly stored.

immersion-lubricated type. Fill the

top

20W

or SAE 30W engine oil

oils

are not

1.

This manual

is

NOT filled

the

factory,

as

a

of

the machined notch cut

to

be used

oil!

CF,

CG-4, CH-4 or CI-4.

in

this

Lubricating oils

gear.

all

LUBRICATION

The

oil

capacity for

quart

(1.0

liter). Check the oil level daily after

been

warmed maintained when housing. stick

in

place.

Change operation minimum.

drain

will

NEUTRAL for approximately

may opening

temperature must

at the

the

dipstick is completely inserted into the transmission

Make sure that

are

in good shape. These 0-rings will keep the dipstick

the

transmission

and

The transmission has a 6 mm Allen Hex wrench

plug

for draining

drain

from

also

be removed

so the oil

the

transmission is approximately 1.0

and

stopped. The oil level should be

top

of

the

machined fiat

the

two

0-ring gaskets

oil

after the first

thereafter every

the transmission, run the engine in

by

may

not

exceed

250

the

oil.

To

make sure most of the oil

10

attaching a pump onto

be sucked out. The operating oil

250"F

on

25

hours of engine

hours or once per year,

to

15

minutes. This oil

(120°

C).

the

engine has

the dipstick

on

the dip-

the

dipstick

CONTROLS

The

only

controls required

single

level remote controled cable. The cable should be attached supplied remote when the into position

1-1/2 the positions.

to

the

gear box lever using the cable bracket

with the unit. Both the gear box lever and the

control lever must be in the NEUTRAL position

the

cable

is

attached

remote

cable

an

FORWARD or into REVERSE from the NEUTRAL

without running out of cable. Allow approximately

inches

of cable throw

transmission's gear box lever

equal

to

operate the transmission is a

to

the gear box lever. This allows

throw

distance

from

the NEUTRAL position on to

to

shift

each of the

the

two

drive

gear box

TRANSMISSION

If

the throw distance (or travel) of the remote cable is short, the gear box lever cannot fully engage into

FORWARD or REVERSE.

transmission's internal clutches will wear prematurely the transmission may over heat and eventually

Excessive throw distance in the remote control level detrimental remote control lever should align with the NEUTRAL ing on

NEUTRAL.

JS

AND

GEAR

SHIFT.

CABLE

to

the transmission. Note that the position of

its

bracket when the transmission

BW

GEAR

BOX

SHIFT

SHIFTING

To

shift the transmission fron

exert a

heavy

push to the remote control lever. A gentle

may

not carry enough force to actually shift the transmission's internal gears. A gentle throw is signalled mission not engaging into the desired drive. Make sure remote season. Shift the transmiss10n while the engine is running

co~trol

1200 rpm or below.

A

CAUTION:

gear

box

this

plate

transmission

ensure

Loosening

transmission

lever

and

equal

of

lever

cover

the

has

throw this warranty.

is

l~b?cated

NEVER

remove

from

actuating level

been

flnely

distance

cover's

In

this situation, the

LEVER

NEUTFl'AL

NEUTRAL

at least once each

or

loosen

transmission.

Inside

adjusted

of

Internal

capscrews

voids

is

really in

irito

the The of

at

the

mechanisms.

too

the

transmission

and

fail.

is

FORWARD

by

the

operating

two-bolt

position

the

factory

the

not

the

mark-

thro~

trans-

the

at

of

to

1-W-IWl:STERBEICE

I EnalllllS & Generators

42

JS

AND

BW

TRANSMISSION

SAILING

The JS and position while sailing. Leaving the transmission in

NEUTRAL

vessel by allowing the propeller is able to freewheel (spin).

However,

while under sail, place the transmission into

OPERATION

BW

transmissions can be left in its

while sailing alleviates unnecessary drag on the

if

one wishes to stop the propeller/shaft rotation

REVERSE.

COOLING

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

of

the bell housing. This water helps to cool the

transmission's lubricating oil.

SHIFT

BELL

HOUSING

AW

WATER

COOLING

Oil

J.S.

and

B.W.

TRANSMISSIONS

6mm

NEUTRAL

LEVER

·COUPLING

DRAIN

PLUG

ALLEN

HD.

SERVICE

If

any seal on the transmission shows signs

the transmission looked dealer. This problem, especially concerning the rear seal, often contributed to an improper alignment transmission's coupling and the propeller shaft's coupling.

Disassembly recommended. should center.

be

of

the transmission in the field is not

If

done

by

at

by

a qualified WESTERBEKE

an

overhaul

an authorized WESTERBEKE service

or

repair is needed, the work

of

leaking, have

of

the

is

MAINTENANCE

Transmission maintenance is minimal. Keep the exterior housing clean, check the fluid level as part routine, and change the fluid every

Periodically inspect the transmission and the cooler for leaks

and corrosion. checking the fluid level look for signs (fluid will appear as strawberry cream).

Make

certain the air vent is clear and when

300 operating hours.

of

your regular

of

water contamination

Lay-up/Winterize

Storage requires special care. Fol.low these procedures:

NOTE:

This operation will usually occur when the engine

water water cooling system is properly winterized. ·

D Clean up the transmission and touch-up any unpainted

areas (use heat resistant paint).

0 Fill the transmission with

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

SAE

30

engine oil to prevent

0 Loosen attaching hardware from the transmission output

flange and propeller shaft coupling flange before removing the

and spray with lubricant.

boat

from the water. Seperate the flanges

0 Inspect the gear shift cable, linkage, and attachments.

of

Look for corrosion

the conduit, and bending

all moving parts.

the end fittings, cracks or cuts in

of

the actuator rods. Lubricate

raw

JS

AND

BW

TRANSMISSIONS

General

Gear

Ratio

(Standard)

Propeller (Direction

Propeller Lubricating

Transmission

Capacity

Shaft

of

Rotation)

Oil

Sump

Case-hardened

intermediate by

servo

double

2.47: 1

Right

handed -standard

See

propeller

SAE

20W/20

not

mix

grades

grades).

1

qts

(1

AP/,

liters)

SPECIFICATIONS

helical

gears

with

an

reverse

gear.

Reversing

disc

system

transmission.

recommendation

or

SAE

30

of

oil

or

CF,

CG-4,

chart

exclusively use

multi

or

SJ.

(Do

lwlWESIFBSBKE

l

out

Englnt111

43

NOTE:

If

the transmission is to be stored (twelve months prevent internal corrosion. Reduce the oil level before putting

the engine back into service.

&'

GeneMtors

or

more), it s.hould be topped

for

a long time

off

with oil

to

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

BORG

WARNER

VELVET

DRIVE

OIL

COOLER

OPTIONAL

TRANSMISSION / 388/FOUR

SHIPMENT

For safety reasons, the transmission

mission fluid during shipment and the selector lever is temporarily attached to the actuating shaft.

Before leaving the WESTERBEKE plant, each transmission undergoes a test run, with Dexron III TI1e

residual fluid remaining in the transmission after draining acts corrosion for at least one year if properly stored.

TRANSMISSION

Check the transmission fluid level on the dipstick.

transmission has not been filled, tinue to use this fluid. During the first 25 hours keep a lookout for any leakage at the bell housing, output shaft and transmission cooler. This fluid should be changed after the first ing hours thereafter and/or at winter lay-up.

as

a preservative and provides protection against

25

hours and approximately every 300 operat-

ACAUTION:

and

the

correct

starting

the

engine.

FLUID

Be

certain

size

cooler

is

not filled with trans-

ATF

fill

with Dexron

the

transmission

is

properly

transmission fluid.

If

the

llI

and con-

of

operation,

is

filled

installed

before

AND

SHIFT

The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward (F), Neutral (N), and Reverse (R) shifting positions. A detent

to center the lever in each position. The gear shift positions at

LEVER

ball located behind the transmission lever must work freely

the helm must be coordinated with those actuating lever through shift mechanism adjustments. An improperly adjusted shift mechanism can cause damage the transmission. actuating lever should ensure proper operation.

Shifting

Place the gear shift in Neutral before starting the engine. Shifting from one selector position to another selector tion may be made at any time below 1000 rpm and in any order. speed. Start the engine and set the throttle at idle speed; allow the transmission fluid to warm up for a few minutes.

Into

Shifts should

428/FOUR

POSITION

of

the Velvet Drive

The

shifting mechanism and transmission

be

free

of

dirt and well lubricated to

Gear

be

made at the lowest practical engine

to

posi-

Neutral

Move the gear shift lever to the middle position.

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

mission. With the control in completely interrupted and the output shaft sion does not tum.

NOTE:

Some transmissions are equipped with a neutral safety

Unless the transmission actuating lever

switch. aligned

in

neutral, the engine starter will not activate.

tl1is

position, hydraulic power is

You

of

the transmis-

is

peifectly

should

Forward

Move the gear shift lever to the forward position. feel the detent. The actuating lever on the transmission

the forward position. The output shaft and the propeller shaft move the boat in a forward direction.

You

should

is

in

Reverse

Move the gear shift lever to the reverse position.

The

feel the detent. the reverse position. The output shaft and the propeller

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

NOTE:

Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine. Reverse always away from the engine. rf'boat moves backwards with

the gear engine! This problem may be a result of

sh(f't

the actuating lever by the gear shift lever.

actuating lever on the transmission

control in the forward position, shut

of

incorrect movement

You

off

should

is

in

is

the

JW"{WESTERBEKE

Engines & Generators

44

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

FORWARD

DAILY

OPERATION

NEUTRAL

TRANSMISSION

ACTUATING

N

LEVER

POSITIONS

N

REVERSE

0 Check the transmission fluid.

0 Visually check the gear shift linkage and transmission.

0 Start the engine

for the fluid to warm.

NOTE:

Too

noise

from

such

cases

in

neutral. Allow a few minutes at idle

low

an

idle

speed will produce a chattering

the

transmission gear and damper plate.

the

idle

speed should be

increased.

In

0 Shift into gear.

A

CAUTION:Shifting

damage back

transmission

ta

idle

the

when

and

engine

gears

damper

shifting

the

damper

above

plate.

gears

plate.

will

1000

rpm

Pulling

save

wear

can

the

cause

throttle

an

the

INSPECTION

0 Visually check for oil leaks at the hydraulic connections.

Check for wear on the hydraulic lines and replace worn.

if

0 Lubricate the detent ball and shift cable attachments.

0 Inspect the shift linkage.

0 Inspect the transmission bolts; retorque

if

necessary.

0 Clean

0 Refill the transmission with

off

the transmission and properly disp6se

used fluid.

DEXRON

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

on

III ATF. The

the transmission model

of

the

0 Check the dipstick for the proper fluid level.

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

into place and

0 Run the engine, shutdown

Il

WARNING:

engine

is

hale.

This

Oil

Capacity

Approximately 2.5 quarts (2.36 liters) will fill most transmissions variables have a direct relationship to the oil capacity. Additional oil will cooler lines.

in the quantity

MAKE RUBBER SCREWED

TIGHT HANDLE

tum

clockwise until finger-tight.)

and

recheck the fluid level.

Never

pull

out

the

dipstick

running.

could

The

CERTAIN

TO

Hat

fluid

will

splash

cause

sever.e

burns.

to

the oil level fill mark on the dipstick. Many

be

required to fill the oil cooler and the

angle

of

installation will make a difference

of

oil required to fill the transmission.

THE

SEAL

IS

THE

--

.....

_1111111;"

while

from

the

dipstick

MAX

A

CAUTION:

transmission ball

positions.

CHANGING

After the initial 50 hour change, the transmission fluid should

be changed at every

winter haul-out. However, the fluid must be changed whenever it becomes contaminated, changes color, cid.

Clutch

failure

will

shift

lever

does

not

THE

TRANSMISSION

300 operating hours thereafter

occur

fully

0 Remove the oil filler cap and dipstick.

0 Remove the oil cooler return line and allow the oil to

drain into a container.

0 Reconnect the oil cooler return line.

0 Use a suction pump to remove the transmission oil

through the filler cap/dipstick hole.

if

the

engage

FLUID

or

the

detent

or

at

smells ran-

Eng'lfles

45

Oil

Temperature

A maximum oil temperature recommended. Discontinue operation anytime sump oil temperature exceeds

PRESSURE

An optional mechanical pressure gauge can

the control panel to constantly monitor the pressure transmission fluid. A normal reading at gear should indicate 95 constant.

&'Generators

GAUGE

230°F (110°C).

of

190°F (88°C) is

be

installed at

2000 rpm in forward

- 120 lb-in2 (6.7 - 8.4 kg-cm

of

.

the

2

) and be

BORG

·

MAINTENANCE

Transmission maintenance is minimal. Keep the exterior housing clean, check the fluid level as part routine, and change the fluid every

Periodically inspect the transmission and the cooler for leaks and corrosion. Make certain the checking the fluid level look for signs (fluid will appear as

str~wberry

WARNER

of

300 operating hours.

air vent is clear and when

of

water contamination

cream).

VELVET

your regular

Lay-up/Winterize

Storage requires special care. Follow these procedures:

0 Drain the water from the transmission oil cooler and

replace it with a proper mixture

NOTE:

This

operation will usually occur when

raw

water cooling system

of

antifreeze coolant.

is

properly winterized.

the

engine

DRIVE

WARRANTY

Service manuals are available from your BORG dealer.

For

BORG

placed ation Therefore torque loads made at low engine speeds. caused by a shock load, any warranty claim will

TRANSMISSION·

NOTES

assistance, contact:

Richmond and Velvet Drive

1208

Old

Norris Road Liberty, Tel.:

SC

29657

(800) 583-4327

WARNER

on

or

fully reversing

is aware

its gears as the result

of

the shock loads that can be

of

the propeller blades while shifting.

and

directional changes should be

If

it

mechanical propeller oper-

is found that a failure was

WARNER

be

denied.

D Clean up the transmission and touch-up unpainted areas

(use heat resistant paint).

0 Fill the transmission with

internal corrosion.

Dexron

III ATF fluid to prevent

0 Loosen attaching hardware from the transmission

output flange and propeller shaft coupling flange before removing the boat from the water. Separate the flanges and spray with lubricant.

0 Inspect the gear shift cable, linkage,

of

Look for corrosion the conduit, and bending

all moving parts.

NOTE:

If

the

transmission

(twelve

fluid

OIL

The continued flow

time, erode the inside occur. These internal cooler leaks will cause one lowing two problems:

1.

2. The raw water will leak into the transmission fluid caus-

Either case requires an immediate response:

1. Install a new oil cooler.

2. Refill the transmission with

months

to

prevent internal corrosion. Reduce

before

putting

COOLERS

Transmission fluid will leak into the flow and be discharged overboard through the engine exhaust.

A

loss

of

transmission fluid will cause the transmission

fail.

ing an increase in transmission fluid. This contaminated fluid will appear as strawberry cream.

will

eventually

the end fittings, cracks

of

the actuator rods. Lubricate

is

to

or

more),

it

should be topped

the

engine back into service.

of

raw water through the cooler will, in

of

the cooler causing cross leaks to

fail.

DEXRON III

and

be

stored for a

attachments.

or

long

off

the

fluid level

of

raw water

The

transmission

ATF.

cuts in

time

with

the fol-

to

A

CAUTION:

occ11r

at resulting BORG

WARNER related

If

TRANSMISSION TROUBLESHOOTING in this manual.

If

needs to take several fluid changes to get rid

Check your dipstick each time until it appears as pure transmission fluid. Change the out the fluid lines that connect to the cooler.

If

need the attention A transmission cooler may last ten years

some circumstances, depending on operating hours, tropical waters, maintenance, etc.

WESTERBEKE recommends having a spare cooler aboard.

torsional

any problems

water has contaminated the fluid, the transmission fluid

be

the transmission fails to shift properly,

System-related

low

engine

speeds

in

damage

to

is

not

responsible

the

vibration

occur

with the transmission, see

cleaned out and replaced with fresh fluid.

of

a qualified transmission service facility.

noises

or

vibrations

which

can

cause

gear

engine

and/or

transmission.

for

total

system·

of

this

type.

of

the contamination.

transmission filter and clean

it

will most likely

or

more but, in

it

might only last half that time.

can

rattle

It

will

46

STANDARD

AND

METRIC

CONVERSION

DATA

PRESSURE

Pounds

Per

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

TORQUE

Pounds-Force

.

Pounds-Force

VELOCITY

Miles

Per

Hour

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Per

Hour. Kilometers Miles Kilometers

Per

Gatlons

Per

Sq.

In

(psi)

(Hg)

(Hg) (H20) (H20J

(H20)

Inches

Feet

(ft-lb)

(MPH)

(Hp)

x

IMP

Liter

US

Liter

BOLT

Bolt

strength

Customary

(strongest).

i.e.; a grade

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

(in-lb)

x

1.609

.745

=Kilowatts

(MPG)

{Km/L}

(MPG)

{Km/L)

HEAD

MARKINGS

classes

(Inch)

The

seven

=

Kilopascals

=psi x =

=Inches =psi x

=

Kilopascals

x

.113

1.356

=

Kilometers

x

.354

x

2.352

x

.425

x

2.352

are

bolts

marl<s

correspond

bolt

will

2.036

Kilopascals

of

Mercury

27.684

(kPa)

=Newton

(Kw)

Meters

x

1.34

•

=

Kilometers

=

IMP

MPG

=

Kilometers

=

us

MPG

embossed

on

are

iden!ifed'by

to

display

five

(kPa)

x

=Hg

(kPa}

x

=

H20

x

4.026

Meters

(Nm)

Per

Hour

=MPH

Per

the

head

markings

two

marks

embossed

.145

=

psi

.2961

=

Hg

x

13.783

=

H.o

=

H20

(Nm)

x

8.85

,.jn-lb

x

.738

=ft-lb

(KPH)

x

.621

=

MPH

.

Liter

(Km/L}

.

·

Liter

(Km/L)

STANDARD

of

each

bolt.

two

to

grade

than

the

eight

actual

less

marks.

LENGTH·DISTANCE

Inches Feet Miles

VOLUME

Cubic Imperial Imperial

Imperial Imperial Imperial Fluid US US US

MASS~WEIGHT

Ounces liounds

TEMPERATURE

Degree Degree

HARDWARE

Metric

boll

strongest.

grade,

(in)

(ft) x

x 1.609 =

Inches

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

{US Quarts Gallons

(oz)

(lb),x

Fahrenheit

Celsius

class

f\umbers

x

.305

(US

25.4

(in')

x

=Millimeters

=

Meters

Kilometers

x

16.387

(IMP

pt)

(IMP

qt}

{IMP

{IMP.

(IMP

29.573

pt)

x

.473

qt)

x .946 =

gal)

x

28.35

=Grams

.454

=Kilograms

(°F) = (°C

(°C)

=

identify

(m)

x

.568

x

gal)

qt}

x 1

gal)

=

Milliliters

=

3.785

(°F

bolts

(mm)

x

3.281

(km)

x

=Cubic

=Liters

1.137

=Liters

x

4.546

..

201

=US

x

1.201

Uters(L)

Liters

=Liters

(il)

(kg)

X

1.8)

-

32) x .56

by

their

x

.0394

=

Inches

=

Feet

.0621

=

Miles

Centlm~ters

(L)

=

Liters

Quarts

=

US

x

.034

x

2.113

(l} x

(L)

x

.035

x

2.205

+

32

strength

x

1.76

(L)

x.88

(L)

(US

Gallons

=

Ounces =

Pints

1.057

=

x

.264

=Ounces

=Pounds

with

10.9

x

.061

=

IMP

=

x

.22

qt)

(US

Quarts

=

Gallons

lhe

IMP

=

x

gal)

=in

pt

qt

IMP

.833

3

x

gal

=IMP

.833

=

qt

IMP

gal

NOTES:

1.

2.

3.

STANDARD

Capsl'9W

Body

1/4·

20

·28

5/16-18

•

24

318·16

-24

7/16-14

·20

1/2-13

-20

9/16-12

•

18

518·

11

·18

314"

10

-1!i

718·

-14

1 • 8

-14

Fornmla

Size

9

(Inches) • (Thread}

NOTE:

radeS

~

U

.....

Use

the

torque

These

torques

Reduce

torques

BOLT & NUT

SAEGrade5

To111ue

R·Lb(Nm)

8(11)

10(14)

.

17

(23)

19(26) 31

(42)

35(47) 49

55 75

85(115)

110 120(163)

150 170(231)

270(366) 295

395 435

590 660

(895)

to.

convert

~rade7

..,,IQ

'

values

listed

are

by

(66) (75)

(102)

(149)

(203)

(400) (536)

(590) (800)

Ft-Lbs

below

based

on

clean,

30%

or

more,

TORQUE

SAE

Grade

Torque

R·Lb(Nm)

10(14)

19

34

55

85

120(163)

167

280(380)

440

660

to

Nm

(Newton

Grade8

L

'"

When

sp80ific

torque

dry

threads.

when

threading

SPECIFICATIONS

6-7

SAE

To111ue

R-lb(Nm)

(26)

(46)

(75)

(115)

(226)

(597)

(895)

105 120

155 170

210 240

375(508)

420 605

675 910

900(1342)

Meters)

values

Reduce

torque

capscrews

Grades

12

(16)

14(19) 24(33)

Tl(37) 44(60).

49(66) 70

(95}

78

(106)

v

(142)

,,

(163) (210)

(231) (285)

(325)

(569) (820)

{915) (1234)

multiply Ft-Lbs

are

not

available.

by

10%

into

when

aluminum.

METRIC

Bott

Dia.

wrench

M3

5.5mm

M4

?mm

M5

8mm

Ma · 10mm

13mm

M9

M10

16mm

M12

18mm

M14

21mm

M16

24mm

27mm

M18 M20

30mm

M22

33mm

M24

36mm 41

M27

M30

46mm

M33

51

M36

55mm

by

1.356.

engine

BOLT & NUT

Grade4.6 Grade4.8

Size

fHb(Nm)

0.3

0.8

81 118 159

203

mm

295 402

mm

546

700(950}

oil

is·11sed.

(0.5)

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

_14(19)

26(35)

37(50)

59(80)

(110)

(160) (215)

(275) (400) (545)

(740)

TORQUE

R-Lb(Nm)

774 992

SPECIFICATIONS

0.5

(0.7)

1

(1.5)

2(3)

4

(5.5)

10(13)

18

(25)

33(45) 55

(75)_

85

(115)

118(160) 166

(225)

225

(305)

288

(390)

417

(565)

568

(770)

(1050) (1345)

Grade

8.8 • 9.8

Ft-Lb(Nm)

1

(1.3)

2(3)

4.5

7.5

(1CI)

is

(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

FHb(Nm}

1.5(2)

3(4.5)

6.5

(9)

11

(15)

35

(26)

55

(75)

97

(130)

151

(205)

232

(315)

321

(435)

457

(620)

620

(840)

789

(1070)

1154

(1565)

1571

(2130)

2139

(2900)

2744

(3720)

Engines

47

& Generators

W

358

·

SPECIFICATIONS

THREE

MARINE

DIESEL

E'NGJNE

Engine Type

Governor

Valve

Mechanism

Combustioa

Bore

Piston Displacement

Firing

Direction

Maximum

Compression Ratio

Compression Pressure

·Valve Seat

Chamber

& Stroke

Order

of

Rotation

Torque

Angle

(at

2300

rpm)

Diesel, four-cycle, three-cylinder, fresh water -cooled, vertical,

in-line (32

Mechanical, centrifugal

Overhead

Swirl

3.07 x 3.07 inches (78 x

68.23 cubic inches

1-3-2

Clockwise,

.

41 lbs-ft (5.67 kgs-m)

23:

455 psi (32

Intake 45° Exhaust

chamber

1

45°

hp

at

when

kg/cm

3600

type

viewed

2

rpm,

(l.118

)

at

320

maximum)

weight

78

mm)

liters)

from

rpm

type

tl;le

front· ·

Valve Clearance (engine cold)

Inclination

Dry Weight

Fuel Consumption

Idle Speed

RPM

Cruise

LUBRICATION

General

Oil Filter

Sump Capacity (includes filter)

Operating Oil Pressure

SYSTEM

Intake 0.010 inches (0.25 Exhaust 0.010 inches (0.25

Height: 21.25 inches (539.75 Width: 18.37 inches (466.60 Length:

Continuous 14° Temporary 25° (not to

368 lbs (166.9 kgs)

1.2 U.S.

800 - 1000

2500 - 3000

Forced lubrication by

Paper element, spin-on type

4.22 U.S. qts (4 liters)

50 - 80 psi (3.5 - 5.6

30.10 inches (764.54

exceed

gph

(4.54 lph)

rpm

running

Maximum

gear

kg/cm

mm)

Max.

mm)

30

min.)

at

2500

rpm

(approximate)

load,

RPM.

pump

2

)'

Oil pressure will vary with engine R.P.M.

3500 - 3600

RPM

Oil Grade

API

Specification

48

CF,

CG4,,

CF-4,

CH-4,

or

Cl-4

or

better.

SAE

10W-40,

or

15W-40

W

358

ELECTRICAL SYSTEM

SPECIFICATIONS

THREE

MARINE

DIESEL

ENGINE

Starting Battery

Battery Capacity

Starting Aid

Starter Motor

DC No-Load

Cold Cranking Current

Alternator

Regulator

FUEL SYSTEM

Fuel

Injection Pump

· Injection Timing

Nozzle

Injection

Current

Starting Pressure

12-Volt, (-)negative ground

400-600 C.C.A.

12-Volt sheathed type glow plug

12-Volt, 1.2 KW, solenoid, actuated shift

60 Amps at 11.5 volts (6500 rpm, min.)

190 Amps at

12-Volt DC, 50 Amps

Internal regulator, built into alternator

Open flow, totally self-bleeding

No.20 grade

Nippondenso (Bosch M type) 23° ± 0.5° BTDC (Static)

Throttle type

2275 psi

(SAE

of

diesel

(160 kg/cm

12

volts

J313)

#45

according

Cetane

to

2

)

or

ASTM

higher

0975.

14.1

Volts

DC+/-

.3

Volts

Lift

Pump

(with filter element)

Fuel Filter (on engine)

Air Cleaner

Air Flow (engine combustion)

COOLING SYSTEM

General Fresh water-cooled block, thermostatically-controlled with

Operating Temperature

Fresh Water Pump Centrifugal type, metal impeller,

Sea Water Pump Positive displacement, rubber impeller, gear-driven

Sea Water Flow, (measured before discharging into exhaust elbow)

System Capacity (fresh water) 6

at

3600 rpm

12-Volt DC; lift capacity 6 ft (1.8

Canister type, with replaceable element

Metal screen type - cleanable

71

cfm (2.0 cmm)

sea water exchanger system

150-170°F · ( 66-77°C)

10

gpm (37.8 lpm) approximate

U.S.

qts (5.68 liters)

rn)

belt~driven

49

W

SPECIFICATIONS

388

FOUR

MARINE

DiESEL

ENGINE

Engine Type

Governor

Valve Mechanism

Combustion Chamber Bore & Stroke

Piston

Displacement

Order

Firing

Direction

Maximum Torque (at 2400 rpm)

Compression Ratio

Compression Pressure

Valve Seat Angle

Valve Clearance (engine cold)

of

Rotation

Diesel, four-cycle, four-cylinder, fresh water-cooled,

vertical, in-line

Mechanical, centrifugal weight type

Overhead

Swirl chamber

2.87 x 3.v1 inches (73 x 78 mm)

79.64 cubic inches (1.305 liters)

(37

hp

type

at

3600 rpm,

maximum)

1-J-4-2

Clockwise,

53

lbs-ft (7.33 kgs-m)

23:

455 psi (32 kg/cm

Intake 45° Exhaust 45°

Intake 0.0098 inches (0.25 Exhaust 0.0098 inches (0.25 mm)

when

viewed from the front

1

2

at

320

)

rpm

mm)

Dimensions

Inclination

Dry Weight

Consumption

Fuel

Idle Speed

RPM

Cruise

LUBRICATION SYSTEM

General

Oil Filter

Sump Capacity (includes filter)

Operating

Oil

Oil Pressure

Grade

Height:

Width: 18.37 inches (466.60 mm) Max.

Length: 33.77 inches (857.76

Continuous 14° Temporary 25° (not to exceed 30 min.)

419 lbs ( 190 kgs)

1.6 U.S. gph (6.05 lph) running at 2500

750 - 950 rpm

2500 - 3000 rpm

Maximum

Forced lubrication

Paper element, spin-on tye

4.75 U.S. qts (4.5 liters)

50 - 80 psi (3.5 - 5.6 kg/cm

API

23.70 inches (601.98

load,

RPM.

Specification

CF,

3500 -3600

by

gear

CG-4,.

pump

2

CF-4,

)

CH-4,

mm)

RPM

or

Cl-4

rpm

(approximate)

or

better.

50

W

SPECIFICATIONS

388

FOUR

MARINE

DIESEL

ENGINE

FUEL SYSTEM

Fuel

Injection Pump

Injection Timing·

Nozzle

Injection Starting Pressure

Lift Pump

Fuel Filter (on engine)

Air Cleaner

Air Flow (engine combustion)

COOLING

General Fresh water cooled block, thermostatically-controlled with

Operating Temperature

Fresh Water Pump Centrifugal type, metal impeller, belt-driven

SYSTEM

Open flow, totally self-bleeding

No.2D ( SAE grade

Nippondenso (Bosch M type) 23° ± 0.5°

Throttle type

227

12-Volt DC; lift capacity 6 ft (1.8 m)

Canister

Metal screen type -

82.9

sea

150-1701°F

J313 )

#45

Cetane

of

diesel

according

BIDC

5 psi (160 kg/cm

type: with replaceable element

din

(2.34 cmm) .

water exchanger system.

(

(Static)

66-77.

to

ASTM

2

)

cleanable

0

C)

or

0975.

higher

Sea Water Pump Positive displacement, rubber impeller, gear-driven

Sea Water Flow; (measured before discharging into exhaust elbow)

System Capacity (fresh water) 7 U.S. qts (6.6 liters)

ELECTRICAL

·Starting Battery

Battery Capacity

Starting Aid

Starter Motor

I?C No-Load Current

Cold .Cranking Current

Alternator 12-VoltDC,

Regulator

at

3600 rpm

SYSTEM

10 gpm (37.8 lpm) approximate

12-Volt,

400-

12-Volt sheathed type glow plug

12-Volt,

60 Amps at 11.5 Volts (6500 rpm, min.)

190 Amps at

Internal regulator, built into alternator

(-)

negative ground

660

C.C.A.

1.2

KW, solenoid, actuated shift

12

Volts

50

Amps

·14.1

Volts

DC

+/-

.3

Volts

.Engln~s

.

~

51

Gfm.e_rators

W

428

SPECIFICATIONS

FOUR

MARINE

DIESEL

ENGINE

Engine Type

Governor

Valve Mechanism

Combustion Chamber

Bore

& Stroke

Piston Displacement

Firing

Order

Direction

Maximum Torque (at

Compression Ratio

Compress~on

Valve

Valve Clearance (engine cold)

of

Rotation

Pressure

Seat Angle

2500 rpm)

Diesel, four-cycle, four-cylinder, fresh water-cooled, vertical in-line (42 hp at 3600 rpm, maximum)

Mechanical, centrifugal weight type

Overhead

Swirl chamber type

3.07 x 3.07 inches (78 x 78 mm)

90.93 cubic inches

(l.49

liters)

t-:5-4-2

Clockwise, when viewed from the front

56 lb-ft (7. 74 kg-m)

23:

l

2

455 psi (32 kg/cm

Intake 45° Exhaust 45"

Intake 0.0098 inches (0.25 mm) Exhaust 0.0098 inches (0.25 mm)

)

at

320

rpm

Dimensions

Inclination

Dry Weight

Fuel Consumption

Speed

Idle

Cruise RPM

Maximum

LUBRICATION

load

RPM.

SYSTEM

General

Oil Filter

Sump Capacity (includes filter)

Operating Oil Pressure

Height:

·width: 18.37 inches (466.60 mm) Length:

Continuous

Temporary 25°

419 lbs (190 kgs)

1.8 U.S. gph (6.81 lph) running

750 - 95Drpm

2500 - 3000 rpm

Forced lubrication

Paper element,

4.75

50 - 80 psi (3.5 - 5.6 kg/cm

23.70 inches (601.98 mm)

33.77 inches

14°

(not

3500 -3600

U.S.

qts (4.5 liters)

RPM.

spin7on type

(857.76

to exceed 30 min.)

by

gear pump

mm)

at

2

)

2500 rpm (approximate)

Oil Grade

NOTE:

Oil Pressure will vary with engine RPM.

API

Specification

SAE

10W-40,

CF,

or

15W-40.

CG-4,.

CF-4,

CH-4,

52

or

Cl-4

or

better.

W

428

.

SPECIFICATIONS

FOUR

MARINE

DIESEL

ENGINE

FUEL SYSTEM

Fuel

Injection Pump

NoZ7le

Injection Starting Pressure

Lift Pump,

Fuel Filter (on engine)

Air Cleaner

lfir

Flow (engine combustion)

COOLING SYSTEM

General Fresh water cooled block, thermostatically-controlled with

Operating Temperature

Fresh Water Pun;ip Centrifugal

. Open flow, totally self-bleeding

Np.20(St.E

grade

Nippondenso (Bosch M type)

Throttle

2275 psi (160 kg/cm

12Nolt

Canister type, with replaceable element

Metal screen type - cleanable

94.0 cfm (2.66 cmm)

sea water exchanger system

150-170i;(.66~77:c

~313)

of

diesel

type·

DC; lift capacity 6

#Mi

aecording

~

type,

metal impeller, belt-driven

Cetane

to

2

)

or

ASTM

ft

(1.8

higher

0975.

m)

{Wet).

Sea Water'Pump Positive· displacement, rubber impeller, gear-driven

Sea Water Flow, (l!leasured before discharging into exhaust elbow) .

System

~ap~ciiy

ELECTRICAL

Starting Battery

Battery Capacity

Starting Aid

Starter Motor

DC No-Load Current

Cold Cranking Current

Altemator

Regulator

at

3600 rpm

(fresh

SYSTEM

10

gpm (37.8 lpm) approximate

w.f!,ter)

. 7 U.S. qts (6.6 liters)

12-Volt, (-)negative ground

400-

12-Volt sheathed type glow plug

12-Volt,

60 Amps at 11.5 Volts (6500 rpm, min.)

190 Amps at

12-Volt DC,

Internal regulator, built into alternator

600

C.C.A.

1.2

KW, solenoid, actuated shift

12

Volts

50 Amps

14.1

Volts

DC·+/-

.3

Volts

Engines

53

& Generators

LAY·UP & RECOMMISSIONING

GENERAL

Many

owners

·

including off-season to

accomplish lay-up preparation themselves.

The

procedures

own

lay-up

check list if others These

during maintenance

If

you

your

local servicing

provide

Propeller

The

transmission

be

opened out of storage severe the

boat

shaft

has

apply

to

not

in

period

Fresh

A

50-50

recommended

This

solution antifreeze, solution

Shoul<;l amount mixture. and

mixture

cooling

Lubrication

With

the sump. with

new

ENGINE

oil

changing procedure.

oil

pressure

A

in

the

combustion

chemicals

internal

rely

on

their boatyards

engines

procedures should afford your engine protection

a lay-up

have

assistance.

the

water or

in

strain

is

actually

small boats that

use,

of

time.

Water

solution of antifreeze

to

more

from

Operate

system.

and

generators, for lay-up during

or

for

long

periods of

which

follow

and

recommissioning, or

do

the

procedures.

and

also

help familiarize

needs

of your

any

questions regarding lay-up procedures, call

Shaft

Coupling

and

up and

the

moved

the cradle. The flexibility of

on

the

taken

out or put

been

unless

they

Cooling

for

use

may

require

depending

make

sure

antifreeze

Jhe.

engine the

of

the

antifreeze concentration

Now

engine.

dealer;

he

propeller half couplings should bolts removed

from

propeller shaft or coupling or both,

in

bent

by

are

hauled out of

have

been

Circuit

in

the

coolant system

a higher concentration of

on

the

area's winter climate. Check

the

antifreeze protection

be

needed,

block

engine

to

recheck

to

inactivity.

will allow

you

will

be

more

[Propulsion

when

land

to

the

water.

these strains. This

dry for a considerable

and

distilled water

drain

and add a more

ensure a

the

antifreeze solution's

System

engine

warm,

drain

all

the

engine

Remove

CAUTION:

and

replace the

oil.

Use

the

correct grade

LUBRICATING

and

make

Do

sump

over

the

deposits

which

can

parts.

oil

OIL

pages

Run

the engine

sure there are

not

leave

the

lay-up

period.

combine

reduce

to

the

filter

of

in

no

engine's

produce

life

prepare their craft,

the

Others prefer

you

to

perform your

may

use

them

you

with

the

than

willing

Engine]

always

the

boat

is

hauled

water,

and

during

the

boat often puts a

In

some cases,

does

the

water

when

is

at

all

times.

is

adequate.

an

appropriate

concentrated

complete

and

oil. Refer to

this

and

leaks.

Lubricating

of

circulation

throughout

oil

fill

manual for

check for proper

old

from

the

engine

the

strength.

the

sump

the

oil

and

harmful

your

engine's

as

a

to

while the

not

the

oil

the

oil

Fuel

Top

or

stabilizer should be

gasoline/water separator and fuel.

Fuel

Top additives mix

Additives.

should be added at

condition used separator primary sediment

Change

fuel

·

for 5 -

system. the needed. allow equipment

Raw

Close hose gallon check the engine

any zinc

Start fresh stop solution slightly stronger protection

Start

through the water circuit from as

Remove antifreeze mixture Examine a cover gasket. until recommissioning, but replace

Cylinder

Spray arrester removed,

oil will stall out the engine spark plugs for winter protection.

System

off your fuel

higher. A fuel

make

System

off your fuel tanks

with

are

system,

10

fuel

movement of

Water

the

from

bucket of clean

the

zinc

anode

the

water through

the

engine.

providing corrosion protection.

fogging oil

[Gasoline]

tanks

with

unleaded

conditioner

added.

certain there

and

are

such

Change

clean

no

leaks.

[Diesel]

with

No. should be added prior the

fuel

being added

such

as

Bio-bor

this

the

fuel.

Care

compatible

used

fuel

bowl.

the

fuel

as

minutes Check for system during

Operating

on

with

in

the

system. Change

filter/water separator clean

filter

elements

needed. Start

to

malre

any

the

engine.

Cooling

through-hull

the

seacock. Place

zinc

anode

found

and

clean or replace it

debris from inside the heat exchanger

is

located. Clean

engine and

in

engine

the

raw

This antifreeze mixture

the

your

area.

and water

freezing

impeller

will

impeller.

Do

not

allow

the

refill

allow

from

Lubrication

into while

and

time

to

control bacteria

should be taken

the

primary

the

sure leaks that this

servicing,

engine

for

treated fuel

Circuit

seacock.

the

fresh

water.

in

the

raw

system.

the bucket

than

neeµed

all

of

system.

during

your

accompany

Acquire a

replace

[Gasoline]

the open air

the

engine

and

gasoline

as

Sta-Bil

the

element

the

metal

Clean

20

diesel

to

topping off

fuel

still

Diesel

Kleen + Cetane

fuel

the

on

the

engine

no

air

is

may

have

correcting

5 -

10

through

Remove

end of

Before

primary

as

required,

raw

water

When

the

with

for

this

nJi.xture

Once

the

should

the

winter

raw

water

it,

so

replacement,

the

impeller

the

cover

intake,

is

running.

coat

the

of

gasoline

bowl.

up

any

fuel.

to

in

the

growth

that

the

filter/water

element

the

separator

and

allow

left

in

been

minutes

the

raw

this

hose

starting

heat

and

strainer.

pump

bucket

an

antifreeze

winter

to

bucket

protect

lay-up,

pump

catch

if

(into

and

with

valves,

89

octane

in

your

Re-install

spilled

Fuel

ensure

they

tank.

Boost

and

additives

in

your

bleed

the

it

to

run

the

fuel

created

them

as

will

help

injection

water

intake

into a five

the

engine,

exchanger

also

clean

where

the

to

draw

the

is

empty,

freeze

be

drawn

is

empty,

the

raw

as

(some

it

in a bucket).

needed,

the

pump)

gasket.

the

flame

The

fogging

cylinders

in

on

stop

well

and

54

LAY·UP

&

RECOMMISSIONING

Cylinder

If

you anticipate a long lay-up period (12 months or more) WESTERBEKE recommends removal access to the cylinders. Squirt light Marvel Mystery oil into the cylinder walls. Rotate the engine crankshaft revolutions and re-install the glow plugs.

If

your engine does not have glow plugs, the injectors will have to be removed. the injectors and return fuel line as needed.

Intake

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

Starter

Lubrication and cleaning if

access to the starter permits its easy removal. Make sure the

battery connections are shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.

Lubrication

Be

sure

Manifold

[Gasoline]

Motor

[Diesel]

of

the glow plugs for

by

hand two

to have replacement sealing washers for

of

the starter drive pinion is advisable,

Batteries

If

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

A

WARNING:

highly-explosive arcing

or a lighted

smoke

or

allow serviced. to

Drive

Loosen the alternator, water pump and governor drive belts. Inspect and re-tighten at recommissioning Clean off loose paint and corrosion, prime and repaint.

Spare

Lay-up time provides a good opportunity to inspect your Westerbeke coolant hoses need replacement. Check your basic spares kit

and order items not on hand, or replace those items used tluring the lay-up, such as filters and zinc anodes. Refer to the

PARTS

Shut

prevent

Belts

Parts

engirte to see

section

electrical

of

on

Lead

acid

gas,

which

cigarette,

an

open

flame

off

all

electrical

arcing

if

this manual.

board during the lay-up period,

If

there is any doubt that the

or

that they will be

batteries

can

during

external items such as drive belts

emit

be

ignited

cigar,

or

near

the

equipment

servicing.

hydrogen,

by

electrical

pipe.

Do

battery

in

the

a

not

being

vicinity

SPARE

Transmission

Check

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

TRANSMISSION SECTION.

[Propulsion

change the fluid

Engine]

in

the transmission as required

up

any unpainted areas.

Recommissioning

The recommissioning

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

1. Remove the oil-soaked cloths from

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

3.

Reinstall the batteries that were removed during the

lay-up, and reconnect the battery cables, making sure the terminals are clean and Check to make sure that

A

CAUTION:

eye

protection

batteries

can cigarette, flame electrical arcing

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

5.

6. Start the engine

or

emit

be

ignited

cigar,

near

the

equipment

during

proper tightness Check the condition

circuit and clean that

it

is not necessary to flush the antifreeze/fresh water solution from the engine is put into operation, the system will self-flush in a short period advisable, as either an end service, to inspect the area where the zinc is located in the heat exchanger area.

in the

PREPARATIONS

manual.

of

your

Westerbeke engine after a

in

the PREPARATIONS

of

the lay-up procedures will need to be

raw

water pump cover and gasket and

that the conneetioas are tight.

the

batteries are fully charged.

Wear

rubber

gloves, a rubber

.when

servicing

hydrogen, a highly

by

electrical

or

pipe.

battery

Do

being

in

the

arcing

not

serviced.

vicinity

FOR

t)l.e

intake manifold.

batteries.

explosive

or a lighted

smoke

or

Shut

to

p.:·event

STARTING

if

required).

apron,

Lead

gas,

allow

off

servicing.

[gasoline].

of

the zinc anode in the raw water

or

replace the anode as needed. Note

raw

water coolant system. When the

of

time with no adverse affects.

of

season or recommissioning

and

clear any and all zinc debris from that

in

accordance with procedures described

FOR

STARTING

section

is

as

and

acid

which

an

open

all

electrical

It

is

of

this

Engines.&.

55'

Oenerstors

CONTACT

YOUR

SUGGESTED

WESTERBEKE

DEALER

SPARE

MARINE

FOR

DIESEL

SUGGESTIONS

PARTS

ENGINES

AND

ADDITIONAL

INFORMATION

RAW

WATER

PUMP:

IMPELLER/GASKET

FUEL FILTER

..

WATER

SE~ERATOR

FILTER

HARDWARE

KIT

WESTERBEKE

each

Kit Kit

packaged "A" "B"

in a

includes

is

for

more

A

Kit

Impeller Heat

Exch~nger

Fuel Filter with Gasket Oil Filter

Drive Belt

Zinc

Anodes

also

offers

rugged

the

basic

extensive

~t

FUEL

PUMP

two

Spare Parts

hinged toolbox.

spares.

off-shore·

Gasket

LIFT.

cruising.

SPARE

Kits,

WESTERBEKERECOMMENOS ENGINE

AND A GALLON

PARTS

Engines & Generators

KITS

OIL

(YOUR

OF

BRANO)

PREMIXED

CARRYING

FOR

AN

OIL

COOLANT.

B

Kit

Impeller Water Thermostat

ZintAnodes Complete

Heat Exchanger Gasket

Injector

Fuel Filter with Gasket

Oil Filter

Drive Belt

Kit

Pump

Kit

Gasket

ENOUGH

CHANGE

Repair

Kit

.

Kit

SPARE

(5

QTS.)

56

WESTERBEKE

WESTERBEKECORPORA TION • 150

MYLES STANDISH INDUSTRIAL

WEBSITE: WWW. WESTERBEKE.COM

PARK•

JOHN

HANCOCK

TAUNTON MA 02780

ROAD

412018-1245

Westerbeke W35B, W 42B, W38B Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual