Westerbeke 40NA User manual

OPERATOR'S MANUAL
WESTERBEKE 40NA
MARINE DIESEL
ENGINE
Publication # 37169
Edition One
February 1988
I

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention
to and emphasize conditions potentially dangerous to the
operator.
fwARNINGi
The above symbol is used In the manual to warn of possible
seriouspersonal injury or loss of IHe.
CAUTION
The above symbol is used in the manual to caution personnel
of possible damage to equipment
Read the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exist and take necessaryprecautions to protect personnel
and equipment
Fuels, exhaust gases, batteries, electrical equipment, and
moving and hot parts are potential hazards that could result in
serious personal
injury or death. Follow recommended proce-
dures carefuUy.
AJways operate bilge blowers for at least five minutes before
startinga gasoline-fueled engine; ensure no gasoline fumes are
presentbefore starting.
• Prevent Electric Shock
Shut off electric power before accessing electrical equip-
ment
Useinsulated mats whenever working on electrical equip-
ment
Make sure your clothing is dry, not damp (particularly
shoes), and keep your skin surfaces dry when handling
electrical equipment
Remove wristwatch and jewelry when working on electri-
cal equipment.
Do not connect utility shore power to vessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch. Damage to vessel's AC generator may result if this
is not done.
Be extremely careful when working on electrical com-
ponents. High voltage can cause injury or death.
• Exhaust Gases AreToxjc
Ensure that the exhaust systemisadequate to expel gases
discharged from the engine. Check exhaust system
regularly
for leaks and make sure the exhaust manifolds
are securelyattached
and no warping exists.
Be sure the unit and its surroundingsare well-ventilated.
• Use ExtremeCareWben Handling Engine Fuel
(A constantdanger of explosion or fire exists)
Do not fill fuel tank(s)whilethe engine is running.
Do not smoke or usean open flame near the engine orthe
fuel tank.
• po Not Alter or Modify the Fuel System
Be sure all fuel supplies have a positive shut-offvalve.
Be certain fuel line fittings are adequately tightened and
free of leaks.
Make
sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use. Ex-
tinguishers rated ABC bythe NFPA are appropriate for all
applications encountered in this environment
• UseExtreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.
Lead acid batteries emit hydrogen,a highly-explosivegas,
which can be ignited by electrical arcing or by a lighted
cigarette, cigar,
or pipe. Do not smoke or allow an open
flame near the battery being serviced. Shut off all electri-
cal equipment in the vicinity to prevent electrical arcing
during servicing.
• Avoid Moyjog parts
Do not service the unit while the unit isrunning; If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments,use extreme care to avoid moving
parts and hot exhaust system components.
Do not wear loose clothing or jewelry when servicing
equipment;avoidwearingloose jackets, shirts or sleeves,
rings, necklaces, or bracelets that might be caught in
moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
place at all times.
Do not check fluid levels or the drive-belt'stension while
the unit isoperating.
Do not work on the equipment when mentally or physical-
ly incapacitated by fatigue. ·
I

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Productsoftwareof all kinds, such as brochures, drawings, technical data, operator'sandworkshop manuals, .
partslistsand parts price lists (and other related information), instructions and specifications provided from
sources otherthan
Westerbeke, is notwithin Westerbeke's control and, accordingly, is provided to Wester-
bekecustomersonlyasacourtesyand service. WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CON-
TENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING THE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF, ANO WILL IN NO
EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH, OR
ARISING OUT OF, THE FURNISHING OR USE OF SUCH SOFTWARE.
For example, components and subassemblies incorporated into Westerbeke's products and supplied by
others (such
as engine blocks, fuel systems and components, transmissions, electrical components, pumps
and otherproducts) are generallysupported bytheirmanufacturerswith their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software,
however, may be outdated and no longeraccurate. Routine changes made by Westerbeke's suppliers, of
which Westerbeke
rarely has notice in advance, are frequently not reflected In the supplier's software until
aftersuch changes
take place.
Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software, andtheunavoidableexistenceof
earlier, non-current Westerbeke softwareeditions In thefield. Ad-
ditionally, most Westerbeke products include customer-requested special features thatfrequently donot In-
clude complete documentation.
Insummation, productsoftwareprovidedwith Westerbeke products,whetherfromWesterbeke orother sup-
pliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product
It not only makes good sense, but Is Imperativethat appropriate representatives of Westerbeke orthe sup-
plier in question be consulted to determine the accuracy and currency ofthe product software being con-
sulted by the customer.
1 Westerbeke Diesel Engines

FOREWORD
Thank you forselecting a Westerbeke marine product foryour use. We atWesterbeke are pleased to have
you as a customer.
Read this manual carefullyand observe all safetyprecautions Included throughout. Operating procedures,
periodic
preventive· maintenance procedures, installation checks, system descriptions and minor adjust-
ment procedures
are Included herein so you can operate yourequipment safely and property, maintain the
equipment at ahigh level of efficiency, and expect dependable performance and long service life
in return.
Should yourunit require special attention, contactyourWesterbeke dealer tor assistance. TheWesterbeke
Service Organization is trained
to provide the support necessary to ensure long-term dependable perfor-
mance.
If, within 60 days of submitting the Warranty Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering yourwarranty, please contact the factory In writing with
Model information, including the engine's serial number and commission date.
tram: IESTERBEKE CORPORATION
AVON INDUSTRIAL PARK
AVON. Ill 02322
TDD: ........ - .. ft .....a·---=_,...,
Mail To:
Inspection of Equipment
CUSTOMER IDENTIFICATION
Ada• S•ith
85 Maple S\reet
Aldo, IN 12234
Medel V 4HA
EapirH 7/7/88
Ser. a 1234C78'
The engine is shipped from the factory mounted securely and property crated. Accessory equipment is
shipped in a
separate small box, usually packed within the engine's crate.
Beforeaccepting shipment oftheengine from thetransportation company, the crate should be opened and
the contents inspected for concealed damage. Ifeither visible or concealed damage is noted, you should
require that the delivery agent sign "Received in damaged condition" on the proper delivery receipt. Also
checkthecontents ofthe shipment againstthe packing list
and make sure thatthe proper notation is made
if any discrepancies exist. These noted discrepancies are yourprotection against loss or damage. Caims
conceming loss ordamage mustbe made to thecarrier, not to the Westerbeke Corporation.
Westerbeke Diesel Engines 2
I
...

TABLE OF CONTENTS
Section•............•.•..•........•...............•............•.................Page
W 40NA MARINE DIESEL ENGINE
GENERAL SPECIFICATIONS .••...••••••••..••.•••••••.•...••..••••••••• 7
W
40NA SYSTEM SPECIFICATIONS···························-···8
INSTALLATION CHECKS ..••..•..•••.•.••.•...••....•••..•••••••...•.••.. 10
PREPARATION FOR STARTING ...••...••.....••••.......•••.•••••.• 22
DESCRIPTION OF INSTRUMENT PANEL •••••••.•.•.•••••••••. 24
STARTING PROCEDURE •.............•...••..••.••.••.••••.•.•...•••.•.. 26
STOPPING PROCEDURE •••.•••••.••••••.••••••••••••••••••••••••••••••• 28
FUEL SYSTEM ················································-··············· 31
ELECTRICAL SYSTEM .•••••••••••••.•••••••••••••••.•••••••••••••••••••••. 37
DC CONTROL CIRCUIT
WIRING DIAGRAM # 37248 ..••••••••..••••...•.••••••••.•. 40 and 41
COOLING SYSTEM •.•••..•••.••..••••••••••.••.•••.••..••••••••••••••••••••. 42
LUBRICATION SYSTEM •••.•...•....••..•.••...•....••..•......••..••.... 47
HBW 150 TRANSMISSION .....••......••....•.•...•...........•....... 50
ENGINE TROUBLESHOOTING ...•...•....••......•...•...•....••.•.• 54
MAINTENANCE & ADJUSTMENTS •.••••••••..••..••••••..••••.•.•• 57
VALVE CLEARANCE ADJUSTMENT ..•.••••••••••.•.••.••.•..•...• 60
TORQUE SPECIFICATIONS .•..•....•.••.•..••••••••.•......•..•••.•..• 61
GENERAL TORQUE TIGHTENING CHART •••••••.•••••••••... 62
LAY-UP & RECOMMISSIONING ..••........•.••..•••.....••.•••••.•• 63
INDEX ••••••••• : ••.•••.••••••••.•••••••••.••••.•••••••••.•••••.•.••••.••.•••..••••.•• 67
PARTS UST ••.....••..••.•...•.........••...•.•..•....•••.•••.••......•...•...... 99
3 Westerbeke Diesel Engines
I

GENERAL
Introduction
This manual containsthe equipment operating procedures as well as additional information needed to help
the operator keep the equipment in properworking order. Study and follow the instructions carefully. A
planned maintenance program isincluded inthis manual; adhering
to the programwill result in betterequip-
ment performance and longerequipment life. Proper diagnosis of a problem is the most important step to
satisfactory repair; therefore. a troubleshooti.ng table is included.
Understanding the Diesel Engine
The diesel engine closely resembles the gasoline engine, since the mechanism is essentiallythe same. The
cylinders are arranged above a closed crankcase;
the crankshaft is ofthe same general type as that of a
gasolineengine; and thediesel engine hasthe same
type ofvalves. camshaft, pistons, connecting rods, and
lubricating system. ·
Therefore, to a greatextent, adiesel enginerequires the same preventive maintenanceasa gasolineengine.
The
most importantfactors are properventilation and proper maintenance of the fuel, lubricating and cool-
ing systems. Replacement offuel and lubricating filter elements at the time periods specified is a must, and
frequent checking for contamination (that
is, water, sediment, or algae) in the fuel system is also essential.
Anotherimportantfactoristhe useof the same brand of highdetergentdiesel lubricatingoildesignedspecifi-
cally fordiesel engines. Be careful not to put gasoline inthe diesel fuel tank(s). Gasoline does nothavethe
same lubricating qualities asdiesel fuel; consequently, gasoline inthefuel lineswill damage components in
the fuel lift
pump assembly, fuel injection pump and injectors.
The diesel engine does differfrom the gasoline engine, however, in its handling and firing
of fuel. The car-
buretor and ignition systems are done awaywith and in their place are two components -thefuel injection
pump
and the fuel injectors.
Ordering Parts
When contacting yourWesterbeke dealer, partsdistributor, or the factory concerning your Westerbeke unit,
alwaysprovidetheengine'smodel and serial number, andtransmission numberas
they appearonthe black
and silver 'Westerbeke" plate which is mounted on the engine's exhaust manifold. When ordering parts for
your Westerbeke engine, be sure
to insist upon Westerbeke factory packaged parts, because ''will fit'' or
generic parts are frequently notmade to the same specifications as original equipment.
Note that component locations in the manual are referenced from the front
of the engine which is the pul-
ley/drive belt end. (The flywheel/transmission end is the rear end.) Left and right sides are determined by
theengine; imagine straddling the engine and facing in the same direction as the front of the engine: the left
side is at your left, the right side is your right ·
Westerbeke engines and generator sets are thoroughly checked and given a final run undervarious load
conditions before leaving the factory. Test running the engine ensure depenqable operation. long service,
and a satisfied owner.
care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel engine
capable
of manythousands of hours of dependable service. However, whatthe manufacturercannot con-
trol is the treatmentthe unit receives in thefield. That part is up to the owner/operator.
Westerbeke Diesel Engines 4
I

W 40NA Marine Diesel Engine
45° Exhaust Elbow
Flow-Control
Starter with Solenoid
5
Transmission
Cooler
Transmission
Drain
Westerbeke Diesel Engines
I

W 40NA Marine Diesel Engine
Top Lube Oil Fill
20
Amp DC Circuit Breaker
Secondary Fuel Filter
.Fuel Lift Pump
Westerbeke Diesel Engines 6
Thermostart Device
(Optional)
DC Charging
Alternator
I

W 40NA MARINE DIESEL ENGINE
EngineType
Governor
Valve Mechanism
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
MaximumTorque (at 3000 rpm)
Compression Ratio
Compression Pressure
Valve Seat Angle
Valve Clearance
(engine cold)
Dimensions
Inclination
DryWeight
Engine Speed
Fuel Consumption
GENERAL SPECIFICATIONS
Diesel, four-cycle, four-cylinder, fresh water cooled,
vertical, in-line (37
hp at 3000 rpm maximum)
Integral
of the injection pump, mechanical flyweight type
Overhead
Swirl chambertype
3.125 x3.5 inches (79.37 x88.90 mm)
107.4 cubic inches (1.760 liters)
1-3-4-2
Clockwise, whenviewed from thefront
79 lb-ft (10.92 kg-m)
22:1
450 psi (31.63 kg/cm2) at 250 rpm
lntake45°
Exhaust45°
Intake 0.012 inches (0.3 mm)
Exhaust 0.012 Inches (0.3 mm)
Height: 26.81 Inches (680.97 mm)
Width: 31.94 Inches (811.27 mm)
Length: 39.07 inches (992.37 mm)
Continuous 17°
Temporary25° (not to exceed 30 min.)
511 lbs (231.7 kgs)
Idle speed: 750-1000 rpm
Cruising speed: 1800- 2200 rpm
1.0 U.S.
gph (3.? lph) running at
2500 rpm (approximate) when the propeller
allows 3000 rpm
at full open throttle while
underway in forward gear.
7 Westerbeke Diesel Engines
I

W 40NA SYSTEM SPECIFICATIONS
FUEL SYSTEM
Fuel
Injection Pump
InjectionTiming
Injectors
Injection Pressure
Lift Pump
Fuel Filter (on engine)
Air Cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
Sea Water Pump
Sea Water Flow, at 3000 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil Fiiter
Sump Capacity
Westerbeke Diesel Engines
No. 2 diesel oil (cetane rating of
45 or higher)
C.A. V. Mechanical Governed
22" BTDC (StaticTiming)
Pintletype
2205 psi
(150 kg/cm2)
Mechanical diaphragm type
Canistertype, with replaceable element
Metal screen type -cleanable
92 cfm (2.6 cmm) at 3000 rpm
Fresh water-cooled block,
thermostatically-controlled
with sea water exchanger system
170 -190° F (77 - 88° C)
Centrifugal type, metal Impeller, belt-driven
Positive displacement, rubber impeller, gear-driven
8.5 gpm ( 9.0 lpm) approximate
10 U.S. qts (9.5 liters)
Pressure feed, rotortype, driven by spiral gears
from crankshaft
Full flow, paper element, spin-on type
8
4.0 U.S. qts (3.8 liters) not including filter or
optional oil cooler kit
I

W 40NA SYSTEM SPECIFICATIONS
Operating OU Pressure
OD Grade
ELECTRICAL
SYSTEM
Starting Battery
BatteryCapacity
Starting
Aid
Starter Motor
DC No-Load Current
Cold Cranking Current
Alternator
Regulator
TRANSMISSION
General (HBW Standard Transmission)
Gear Ratio (Standard)
Propeller Shaft
Direction of Rotation
Propeller Recommendations
(using standard Transmission
1.88:1 reduction)
Lubricating Fluid
Transmission Sump Capacity
30 - 60 psi (2.1 - 4.2 kg/cm2) at maximum engine rpm
and at normal operating temperature
API specification CC or CD
12-Volt, 125 A-H, (-) negative ground
(recommended)
(150 A-H cold areas)
125 - 155 (Ampere-Hours)
C.A. V. thermostart, 12-Volt
12-Volt, 1.6KW, solenoid, actuated shift, reduction geared
100 Amps at 11.5 Volts (3000 rpm, min.)
125 - 175 Amps at 10 Volts (250 rpm, min.)
12-Volt DC, 51 Amps
Internal regulator, mounted on alternator
Case-hardened helical
gears, with servo-
operated multiple disc clutch
1.88:1
Right handed -standard transmission
18 Dx 1
OP- 2 blade or 18 Dx 8P -3 blade
propeller should allow the engine
to reach its
full rated RPM (3000 + 000 - 100) at full open
throttle while underway in forward gear
ATF -type A orDextron II
0.60 U.S. qts (0.56 liters) approximate
9 Westerbeke Diesel Engines
I

INSTALLATION CHECKS
General
Because thecrafts In whichWesterbeke engines are installed vary in design, installation procedures will vary
according to your craft's specific design. It
is not the intent of this section toadvise boatyards or installers
onprocedures al readywell-developedandwell-understood. However, it is importantthattheowner/operator
realize there are details ofthe installation which require periodic checks to ensure the best operating condi-
tions forthe equipment and
safe operating conditions for the personnel on board. Properlocation and in-
stallation of the diesel engine In the vessel are of prime importance.
Factors
In the Installationthat must be considered are ventilation, to aid In cooling and to provide airfor en-
ginecombustion; exhaust
system, to properlydischarge raw cooling water, quietthe exhaust and expel ex-
haust gas; cooling water supply; fuel supply; and electrical connections.
CAUTION
For safety reasons, the engine and transmission are NOT filled with lubricating oil for ship-
ment. Beforeleavingthefactory, however, each engine withtransmission Is thoroughly tested
with oU in It. This testing, among otherthings, provides all internal parts with a coating of oil.
This on acts as a preservative, providing reliable protection against corrosion forat least one
year ifthe engine and transmission are properly stored.
Location
The locationshould be suchthatIt Is dry, and In an area where bilgewaterorwaterfrom above cannot splash
on the engine. The engine should be properlyventilated and accessible for minorservicing and repairs (ac-
cess for major repairs should be given consideration as well). The location must be properly ventUated to
provide fresh airfor engine combustion.
The engine's lubrication oil sump dipstick, the fresh water and oD
fills, and the transmission's dipstick and transmission or oil fill port must be accessible.
COCKPIT
CABIN
IM8TALLAT%DM AMCLE
NU8T llDT EXCEED J.7 •
Please note thatthe engine's installation angle cannot exceed 17° from the horizontal plain.
Westerbeke Diesel Engines
10
I

Rigging and Ufting
The engine is fitted withlifting eyes. Rope orchain slings capable of supporting the engine'sweight should
be attached to the eyes and the engine lifted by means of tackle attached to these slings. The lifting eyes
havebeendesigned to carrythefullweightoftheengine;therefore, auxiliaryslingsarenotrequired ordesired.
CAUTION
Slings must not be so short as to place significant sheer stress on the engine's lifting eyes.
Strain placed on the engine's lifting eyes bythe lifting sling must not be in excess of 10° from
thevertical plain.
ENGINE
BLJ:•G LJ:f'TJ:NG
AMCLE WU8T NOT
EXCEED so•
LIFTING
EYE
The general rule in moving engines is to see that all ofthe equipment used is amply strong and firmly fixed
in place. Movethe engine a littleatatime
and see that It is firmly supported. Eliminate the possibility of ac-
cidents byavoiding haste. Do not lift the engine by Its propeller coupling, or pryagainstthis coupling with
a crowbar, because excessive pressure of this type maydistort the coupling.
In certain situations itmay be necessarytoliftthe engine in positions otherthan the horizontal position. Cer-
tain situations exist bywhich the engine must
be lowered endwise through a small hatchway which cannot
be made larger. Under these conditions, ifthe opening ofthe hatchway is extremely narrow,
It is possible
to reduce, to someextent, the outside dimensions of the engine by removing external components such as
the alternator, the cooling system's piping, the heat exchanger, certain
fdters, the mounting lugs and other
obstructive equipment. This accessory equipment should be removed bya competent mechanic and spe-
cial care should betaken to avoid damaging any exposed parts. In addition, be careful not to allowdirtfrom
enteringanyopening created bytheremoval ofequipment. Parts removed should bereturnedtotheirrespec-
tive position as soon as the engine has cleared the hatchway.
In case itbecomes necessary to hoisttheengine eitherfront-end upwards ortransmission-end upwards, the
attachmentofslingsmustbedonecarefullytoavoid the possibilityofdamagingthepartsonwhichtheweight
may bear. Special rigging work is best done by someone experienced and competent
in handling heavy
machinery.
11 Westerbeke Diesel Engines
I

Engine Bolts
Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the engine's
flexible mounts. Less preferred arelag screws because theirhold on the wood is weakened every time they
are moved, whereas thehangerbolts stay In position. Ifthe nut on topofthe hanger bolt Is removed toallow
the engine to be lifted from its resting place, the hanger bolt itself remains in place as a stud. Consequent-
ly, the bond between the hangerbolt and thewood is not weakened bythe removal ofthe nut orthe engine.
Foundation forthe Engine
A good engine bed contributes much toward the satisfactory operation of the engine. The engine's bed
must be rigidlyconstructed and neitherdeflect nortwist when it Is subjected tothe engine'sweight ortothe
pressures that the boat may experience while operating In rough seas. The bed must keep the engine's
alignment within one ortwo thousandths of an inch of this position at all times. The bed has to withstand
the forward
push of the propellershaftwhich pushes against the thrustwasher bearing which finally pushes
against the engine's bolts and bed.
In fiberglass hulls, we recommend that similar wooden stringers as in wooden hulls be formed, fitted, and
then glassed securely to the hull. This allows the hanger bolts to be Installed firmly In the wood, thereby
reducing noise
and transmitted vibration.
The engine support stringers must be as wide orwiderthan the engine mounting Isolator. Isolatoroverhang
and/or rounded stringer surfaces
are detrimental tothe isolators' abilitytoretain vibration.
Preformed fiberglass engine
beds, when used, should be of sufficient thickness to property supportthe en-
gine and should be well-glassed tothe hull when
Installed.
The temptation to Install the engine on a pair of
fiberglass angle Irons must be resisted. Such
construction will allow engine vibration to pass
through to the hull. Flexiblemountsrequireafirm
foundationagainstwhichtheymustact
If they are
to perform their function. When possible, follow
bed design A and avoid bed design B (refer to
the illustration).
Supports between the bed stringers, and extend-
ing fromthestringersto the· hull, may be required
forpropersupport and toaid In theabsorption of
vibrations.
Westerbeke Diesel Engines _
Note:
12
BAD
Avoid excessive heigh~, uae
solid stringer cons~ruction (A).
I

._..,
Propeller Shaft Coupling
Thepropeller shaft coupling fitted tothetransmission's output flange must transmit not onlythe power ofthe
engine totumthe propeller shaft
and propeller, but must also transmit the thrust ofthe engine/transmission
either
ahead orastern.
The coupling bore should
be carefully machined for aslight forced fit ontothe shaft and an accurate mating
surface forthe coupling to the output flange
of the transmission.
TheW
40NA engine isequipped with a Federal Flexible Coupling. The Federal Flexible Coupling consists of
a metal hub
and a flange. The hub Is accurately bored to accept the rubber bushings, and the face of the
flange Is machined to match the engine's coupling. The neoprene rubber bushings have a bonded Inner
brass sleeve and the entire bushing Is pressed intothe flange usingthe correct compression pressure. Alloy
steel spiderpins screwthrough the bushings into the hub which are locked into position. The rubber bush-
ingsare ample toabsorbvibration from the propeller and toallow aslight angular misalignmentThe Flexible
Coupling is notdesignedtodothe work of a universal joint The engine must be property aligned beforethe
FlexibleCoupling isinstalled. After the coupling has been installed, the couplingwill compensateformisalign-
ments
caused byhull distortion and from engine movement. The Federal Flexible Coupling will absorb both
thrust and torsional
loads. The pins and rubber bushings are replaceable In case of damage.
When ordering replacement parts, refer tothe Parts List at the back ofthis manual.
Propeller
The type and size of propeller varies with the gear ratio and must be selected to flt the application, based
uponboat tests. Toutilizethe full power of the engine, and toachieve ideal loading conditions, use apropeller
which will permit the engine to
reach Its full rated RPM atfull throttle while under a normal toad and while It
Is moving the boat forward through the water.
Alignment of the Engine
Theenginemust be exactlyaligned with the propeller shaft usinga solid coupling beforeinstallingthe Federal
Flexible. No matterwhat material is used to buUd aboatthe material wUI befound to be flexible to some ex-
tent; hence, the boat's hull will change its shape toagreater extent than Is usually realized when the boat is
launched and operated in the water. Therefore. it becomes extremely important to checkthe engine's align-
ment at frequent intervals
and to correct any errors when they appear.
Misalignment between the engine and the propeller shaft often creates serious problems which are often
blamed on other areas suspected of
causing the trouble. Misalignment will cause excessive bearing wear,
rapid shaftwear and will, in many cases, reduce the life of the boat's hull by loosening the hull's fastenings.
A bent propeller shaft
wUI have the exact effect as those just stated; therefore, a perfectly straight propeller
shaftIs absolutely necessary.
One particularly annoying result of misalignment may be leakage oftransmis-
sion oil through the transmission's
rear oil seal.
Neverattempt afinal alignment with the boat on land. The boat should .be in the water and have had an op-
portunitytoassume its final water form. The best time to perform the propeller shaft/transmission coupling
alignment is with the
fuel and water tanks about half full and all the usual equipment on board, and afterthe
main mast
has been stepped and the final rigging has been accomplished.
.
13
Westerbeke Diesel Engines
I

Take plenty of time in making this alignment and do
not be satisfied withanything lessthan perfect results.
The alignment Is correctwhen the shaft can be easily
slipped backward and forward Into the counterbore,
and when a feeler gauge Indicates that the flanges
come together at all points. The alignment between
the propellershaftcouplingand
the engine's coupling
can contain an error no greaterthan one thousandth
of an inch per Inch of the coupling diameter. For ex-
ample, if your propeller shaft coupling Is three inches
indiameter,themaximumerror that can be allowed. in
the alignment Is threethousandths of an inch (.003).
In making the final check for alignment, the
engine's half coupling should be held In one
position and the alignment with the propeller
coupling tested with the propeller coupling in
each of four positions(A), whDe rotated90° be-
tween each position. This test wm also check
whether the propeller'shalf-couplingisin exad
alignment on Its shaft. Then, keeping the
propeller coupling In one position, the align-
ment should be checked by rotating the
engine's half-coupling in 90° increments,
checking dimensionA while in each 90° posi-
tionuntil the half-coupling has beenrotated. full
circle. · ·
The engine's alignmel should be rechecked
after
the boat has been in service for one to
three weeks and, If necessary, perform the
alignment again. Usually It wDI be found that
theengineis no longer in alignment. This does
not mean that the work has been done Im-
properly at first; rather, It meansthat the boat
hastakensometime to take itsfinal shapeand
that the engine's bed and stringers have
probably absorbed some moisture. It may
even
be necessary to realign the coupling hal-
ves again at a latertime.
Westerbeke Diesel Engines
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.883 FEELER C:AC:E
PROPELLER SHAFT

Exhaust System
The exhaust system provides an outlet line tovent engine exhaust gases out of and away from the vessel.
The system also discharges sea waterwhich has passed through the engine's sea water circuit by mixing it
with hotexhaust
gases. This mixing helps cool the exhaust gases and exhaust elbow and plumbing. The ex-
haust system and the sea water supply tothe exhaust must be configured to prevent the siphoning of sea
water intothe exhaust through the sea watercooling circuit and to prevent the entry of sea water Into the ex-
haust throughthe circuit's through-hull discharge port. If not prevented, sea water enteringthrough the dis-
charge port can fill the exhaust system muffler and enter the engine's cylinders. This will prevent proper
starting
and possibly cause damage to internal engine components.
The sea water supply hose tothe exhaust system water Injection elbow should be routed Oooped) at least
12 Inches abovethe vessel water line. An anti-siphon break should be installed, when needed, at the top of
this loop. The top of the loop should be placed high enough above the vessel's water line so as to remain
above the waterline when the vessel is underway, no matterwhat the angle of heel orroll may be.
Installation witll exhaust
manit01dJwater0 in1ectac1 elbow
ata minimum of s• at:>ove
vessel waterline.
Installation with exhaust
manitotd1water·in1ected elbow
at
or belowvessel water line.
NOTE: Theengine·s heat exchanger
outlet will determine the 'k - or 1•
d1mens1on tor the vented IOop.
Hydro·Hush
48" max.
I
~J
CAUTION: Vented loop must be
in a location wnere II will remain
at:>ove thewater hne during all
attitudes ottne vessel·s operation.
The sea water supply through-hull sea cock fittings must be ofthe flush-hull type. H1gh-speed scoop type
offittings should not
be used as theytend to encourage siphoning. ·
The exhaust discharge from the waterlift muffler should be routed well above the water line then downward
to the through-hull discharge. This routing wOI prevent sea water entry if the through-hull discharge fitting
becomes submerged when the
vessel heels orrolls while under way, or Is subjected tofollowing sea condi-
tions. Refer to the figures shown above for recommended exhaust system installations.
15 Westerbeke Diesel Engines
I
..

Exhaust Back-Pressure
The exhaust discharge hose must be of adequate size and
minimal run to prevent excessive exhaust back-pressure.
Exhaustback-pressureshouldbechecked beforetheengine
is putintoservice. (Refer to the Ulustration.) Excessive back-
pressure will affect the engine's performance.
To measureforback-pressure, usea mercurymanometer, a
pressure gauge, or a water column. A boatyard
or marine
mechanic should have a manometer ora pressure gauge.
Measure back-pressure at the exhaust elbow when the en-
gine
is runningat3000 rpm. Back-pressure, as measured by
amanometer, apressuregauge, or watercolumn, should not
be overthe following specifications:
NOTE: Otherpressuregaugesmay be available to test
for exhaust back-pressure. Check with a competent
mechanic.
Refer to the pressure specifications below.
A water column can be made bytaking a clear plastic tube
and taping one end of the tube along a yardstick and fitting
the other end ofthe tube with a 1/4 inch
NPT (National Pipe
Tap) pipe fitting.
Measure back-pressure at the exhaust elbow when the en-
gine is running at3600 rpm.
Dimension A cannot exceed 39 inches
of water.
Back pressure, as measured bya gauge instrument, should
not exceed the following specifications:
3 inches of mercury (0.104 kg/cm2)
39 inches ofwater in a water column
(.099 kg/cm2 at 4° C)
22 ounces psi
11/2 psi
\
Exhaust
Elbow
Exhaust
Excessive back-pressure can be caused by a small diameter exhaust hose, a small muffler, sharp bends In
the exhaust hose, improper fittings, water pockets, and a high volume ofwater in the exhaust system due
to the length ofthe exhaust discharge hose. The use of elbows and fittings in the exhaust discharge hose's
routing should be limited since these will create flow restrictions
and contribute to exhaust back-pressure.
The engine'sexhaustsystem mustbe separatefrom anyotherengine's exhaust system. Dry portions of the
exhaust system between the engine's exhaust manifold
and the water injected exhaust elbowmust be insu-
lated to hold in the heat
Westerbeke Diesel Engines
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I

Exhaust System Failures
·._ When the engine's sea water is fed into an exhaust system so that the full stream ofthis water strikes a sur-
face, erosion takes place. This erosion may cause premature tanures. The proper design of either awater
jacketed orwater injected
•wer• exhaust system to prevent this problem requires thatthe sea water inlet be
positioned sothatthe entering stream of sea waterdoes notdirectlystrike a surface. In addition, the velocity
ofthe entering sea water stream should be as low as possible, which can be achieved by having inlet fittings
as big in diameter as possible.
·---·
The bestprotectionagainst exhaust system leaks Is toroutinely inspectthecomplete exhaust system. Check
forleaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating surrounding areas
excessively. If excessive heat is present, correct the situation immediately. If you notice a change in the
sound orappearance ofthe exhaust system, inspect the exhaust system and correct the cause.
Exhaust risers installed off the exhaust manifold should not exceed albs in total weight wtmn rigidly con-
nected. Excessive weight and vibration can result In a manifold tanure and/orthe fracturing ofthe riser from
the manifold at Its attachment. Dry portions ofthe exhaust connected tothe manifold, which laybefore the
water injected exhaust system, MUST be property Insulated to retain the exhaust heat within the exhaust
pipe.
fwARNINGi
Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline en-
gines, carbon monoxide is present in diesel exhaust fumes in less concentration. Carbon
monoxideisadangerous
gas that can cause unconsciousness and is potentially lethal. Some
ofthe symptoms or signs of carbon monoxide inhalation or poisoning are as follOINS:
o Dizziness o Vomiting
o Intense
Headache
o Muscular Twitching
o
Weakness and Sleepiness
o Throbbing in Temples
Ifyou experience any of the above symptoms, get
out into fresh air immediately.
Make sure there are no unnecessary objects suspended from any portion ofthe exhaust lines. Excessive
weight could cause deflection ordistortion ofthe lines, resulting in damage or leaks. Inspect Insulated por-
tions ofthe exhaust system to ensure there is no deterioration ofthe insulation.
Oil Drain Hose
An oil sump drain hose is located at the lower front of the engine. OU may be drained from this hose by
removing the cap and the discharge
end of the hose from the support bracket and lowering the hose into a
container.
The hose cap fitting is 1/4 inch NPT (National Pipe Tap) and can be extended, or have a pump
added, for easier removal ofthe old
oil, ifdesired.
17
Westerbeke Diesel Engines

Connecting Pressure Sensing Devices to Oil Galleries
Oil pressure sensing devices, such as senders and switches, must not be connected to an engine's oil gal-
lery with the
use of extended nipples or tees. The reason is simplythat continued engine vibration causes
fatigue ofthe fittings used to make such a connection. If these fittings fail, the engine loses its oil pressure
and quickly seizes.
When additional sensing devices such as switches or sensors need to be installed that function on engine
oil pressure, thesedevicesmustbebulkhead-mounted and connected tothe oil galleryusing an appropriate
grade of lubricating
oD hose. Any fittings used to connectthe hose tothe gallery must be of steel or malle-
able iron composition.
Brass must not be used forthis application.
AutomaticAlarm System
High WaterTemperature Alarm
A high water temperature alarm buzzer has been supplied with the instrument panel. Ifthe engine's fresh
water coolant reaches 210° F (98.8" C), awatertemperature switch on the engine closes causing the alarm
to emit a continuous signal. Refer to the "DESCRIPTION OF INSTRUMENT PANEL" section ofthis manual
for the location ofthe ala!'"1 in your engine panel, page 24.
Low OD Pressure Alarm
Alow oil pressure alarm switch Is located off the engine's on gallery. This switch monitorsthe engine's on
pressure. Should the engine's oil pressure fall to 1o- 15 psi, the switch will close sounding this same alarm.
In this event, the alarm will emit apulsating signal. Refer tothe "DESCRIPTION OF INSTRUMENT PANEL"
section ofthis manual forthe location of the alarm In your engine panel, page 24.
Cooling System
The engine is fresh water cooled by an engine-mounted heat exchanger. Sea water is used as the heat
exchanger's cooling medium. Sea wateris pumped Intothe exchangerbya sea waterpump, where It cools
the fresh water that circulatesthrough the engine block, and is then injected intothe exhaust elbow, carry-
ing with itthe heat removed from the engine's fresh water cooling system.
Sea water should be supplied tothe sea water pumpthrough aflush-type hull fitting using awire-reinforced
hose betweenthe through-hull fitting and the sea water pump. The sea water should be directed through a
visual-type sea water strainer, which will trap debris before it reaches the sea water pump and the heat ex-
changer, and then be delivered tothe pump. Hoses routed from the through-hull fitting to the strainer and
tothe sea water pumpshould be wire-reinforced to preventthe hose from collapsingwhilethe engine is run-
ning (suctionfromthepump may collapseanon-reinforced hose). The sea waterstrainershould be mounted
at or belowthe waterline to make sure the sea water line remains primed.
Westerbeke Diesel Engines
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