Westerbeke 44 A FOUR-35C THREE User manual

~~ERATO~s
ttJ. G *o
i7 ~
! ~
<.' 6
I.LJ {1'\
-+t *
-¥ ¥-
*
SINCE 19'!11
*
..
OPERATORS MANUAL
FOR THE
44A FOUR • 35C THREE
448 FOUR • 350 THREE
44C FOUR • 35E THREE
MARINE Dl SEL ENGINES
...
PUBLICATION N0.044180
THIRD REVISION
MAY 2012
WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW. WESTERBEKE.COM
~A:f,A(j' Member National Marine Manufacturers Association

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
A wARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness
•Nausea
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, your personne~
and your machinery.
The following safety instructions are in compliance with
theAmerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical 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 procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources
of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out
of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources
of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• 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.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative(-) battery cable to the posi-
tive (
+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which
is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation
of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration
of copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow
of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some
of the symp-
toms or signs
of carbon monoxide inhalation or poisoning
are:
Vomiting Muscular twitching
Dizziness Intense headache
Throbbing in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary
to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards
in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination
of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-1 Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON·BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifoldinjection
port is at or below the load waterline will result in
raw water damage to the engine
and possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation.
Failure to properly maintain a siphon-break can result in catastrophic
engine
damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed
40 page Marine Installation Manual covering gasoline and
diesel engines and generators is provided with each unit sold. Additional
copies can
be obtain off our website in pdf form. www.westerbeke.com
Engines &Generators
iv

TABLE OF CONTENTS
Parts Identification ............................................ .2 Water Heater ..................................................... 24
Introduction ................................................... ...... 3
DC Electrical System ...................................... ... 25
Warranty Procedures......................................3 Alternator Troubleshooting ......................... 25
Serial Number Location .................................4 Battery .........................................................26
Control Panels ............... ; ..................................... 5 Wiring Diagrams/Schematics ......................27
Admirals Panel ..............................................5
Engine Troubleshooting .................................... .29
Captains Panel ...............................................6
Tachometer ...................................................... .. 31
Diesel Fuel, Engine Oil and Engine Coolant.. ..... 7
Engine Adjustments .......................................... .32
Oil Pressure ...................................................7 Testing Engine Compression......................
33
Preparations for Initial Start-Up ............... .......... 8
Starting/Stopping Procedure ............................... 9
Warning Lights, Alarms and Circuit Breaker .... lO
Engine Break-in Procedure .............................. . 11
The Daily Operation .......................................... .12
RPM's Guide ............................................... 12
Fuel Injectors ............................................... 33
Valve Adjustments .......................................34
J.S. and B.W. Transmission .............................. 35
Borg Warner Velvet Drive Transmission ........... 37
ZF Transmissions .............................................. .40
PRM Newage Transmissions ........................... ..43
Maintenance Schedule ..................................... 13
Transmission Troubleshooting ........................ ..45
Cooling System .................................................. 15
Thermostat................................................... 16
Propeller Recommendation Chart. .................. ..46
Lay-Up and Recommissioning ......................... ..47
Raw WaterPump .......................................... 16
Heat Exchanger ........................................... 17
Air Intake/Silencer....................................... 18
Fuel System ..... : ................................................. 19
Fuel Lift Pump............................................. 19
Fuel Filters................................................... 19
44 F E . S 'f' t'
· our ngme pee• 1ca mns ........................ A9
35 Three Engine Specifications ....................... .SO
44 Four and 35 Three Torque Specifications .. . 51
Standard Hardware ........................................... .52
Sealants & Lubricants ...................................... .52
Fuel Water Separator...................................
16
Standard and Metric Conversion Data .............. 53
Clow Plugs...................................................20
Engine Lubricating Oil.. .............................. ....... 21
Oil Change................................................... 21
Oil Pressure .................................................22
Suggested Spare Parts ..................................... ..54
Spare Parts Kits ................................................. .54
Remote Oil Filter.........................................23
1

WATER INJECTED
EXHAUST ELBOW
2DACIRCUIT
BREAKER
REAR
FRONT
DC ALTERNATOR
RAW WATER PUMP
UNIT I.D. PLATE
OIL
PARTS IDENTIFICATION
COOLANT PRESSURE CAP
BLOCK
COOLANT \
DRAIN HOSE ZINC
ANODE
OIL DRAIN HOSE
OIL COOLER
RIGHT SIDE
INTAKE/AIR FILTER
2
THERMOSTAT
ASSEMBLY
WATER HEATER
CONNECTION
FRONT
SIDE OIL FILL
LIFT PUMP
REAR
~TFORAIN

INTRODUCTION
This WESTERBEKE Diesel Engine is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your engine, it is
important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this man-
ual carefully and observe all the safety precautions through-
out. Should your engine require servicing, contact your
nearest WESTERBEKE dealer for assistance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer.
If you are planning to install this
equipment, contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKEWarranty is included in a separate
folder. If, after 60 days
of submitting the Warranty Registry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the engine's
serial number and commission date.
Customer Identification Card
/....-IWESTERBEKE
I
Customer Identification
MR. ENGINE OWNER
MAIN STREET
HOMETOWN, USA
Model 35C THREE
Expires 10/16/98
Ser. #UOOOO-D802
The WESTERBEKE engine serial number is an alphanu-
meric number that can assist in determining the date
of man-
ufacture
of your WESTERBEKE engine. The manufacturer's
date code is placed at the end
of the engine serial number and
consists
of a character followed by three numbers. The char-
acter indicates the decade (A=1960s, B=1970s, C=1980s,
D=
1990s ), the first number represents the year in the decade,
and the second and third numbers represent the month
of
manufacture.
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT
OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED
IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product.
It
not only makes good sense but is imperative that appropriate
representatives
of WESTERBEKE or the supplier in question
be consulted to determine the accuracy and currentness
of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures which, if not properly fol·
lowed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model designation and serial number are
located on a nameplate that is mounted on the side
of the
waterjacketed exhaust manifold. The engine's serial number
can also be found stamped into the fiat block surface located
just above the manual shut-off lever. Take the time to enter
this information on the illustration
of the name plate shown
below, as this will provide a quick reference when seeking
technical information and/or ordering parts.
• MODEL SPEC AVON MA USA SER.NO. •
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase. The crankshaft is the
same general type as a gasoline engine, and the diesel engine
has the same type
of valves, camshaft, pistons, connecting
rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most
important factors are proper ventilation and proper mainte-
nance
of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements must be replaced at the time peri-
ods specified, and frequent checking for contaminants (water,
sediment, etc.) in the fuel system is also essential. Another
important factor is the consistent use
of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method
of handling and firing of fuel. The
carburetor and ignition systems are replaced by a single
component -the fuel injection pump -which performs the
function
of both.
4
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model number and serial number as they appear on
the silver and black nameplate located on the manifold.
You
must provide us with this information so we may properly
identify your engine. In addition, include a complete part
description and part number for each part needed (see the
separately furnished Parts List). Insist upon WESTERBEKE
packaged parts because willfit
or generic parts are frequently
not made to the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTERBEKE dealer
will assist you in preparing an inventory of spare parts. See
the SPARE PARTS page in this manual. For engine acces-
sories, see WESTERBEKE's ACCESSORIES brochure.

ADMIRAL CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch and RPM gauge with an ELAPSED TIME
meter which measures the engine's running time in hours and
in 1/10 hours. The panel also includes a WATER TEMPER-
ATURE gauge which indicates water temperature in degrees
Fahrenheit, an OIL PRESSURE gauge which measures the
engine's oil pressure in pounds
per square inch, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem's voltage. All gauges are illuminated when the key
switch is turned on and remain illuminated while the engine
is in operation. The panel also contains two rubber-booted
pushbuttons, one for PREHEAT and one for START.
RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OF THE PANEL.
HOURMETER:
REGISTERS ELAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
WATER TEMPERATURE GAUGE: THIS GAUGE IS
GRADUATED IN DEGREES FAHRENHEIT AND IS
ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
TEMPERATURE IS 170' -190'F(77°- 88°C).
When the engine is shut down with the key switch turned off,
the water temperature gauge will continue to register the last
temperature reading indicated by the gauge before electrical
power was turned off. The oil pressure gauge will fall to zero
when the key switch is turned off. The temperature gauge
will once again register the engine's true temperature when
electrical power is restored to the gauge.
A separate alarm buzzer with harness is supplied with every
Admiral Panel. The installer is responsible for electrically con-
necting the buzzer to the four-pin connection on the engine's
electrical harness. The installer
is also responsible for installing
the buzzer in a location where it will be dry and where it will
be audible to the operator should it sound while the engine
is
running. The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engine's oil pressure rises above 15 psi (1.1 kg/cm2 ).
/
OIL PRESSURE GAUGE: THIS GAUGE IS GRADU-
ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
ILLUMINATED WHILE THE KEY SWITCH IS TURNED
ON. THE ENGINE'S NORMAL OPERATING OIL
PRESSURE RANGES BETWEEN 30- 60 psi
(2.1 -4.2 kg/em').
KEY SWITCH: THE KEY
SWITCH WHEN TURNED
ON SUPPLIES DC POWER
TO THE INSTRUMENT
PANEL CLUSTER, PREHEAT
SWITCH, EXCITATION
TERMINAL OF THE DC
CHARGING ALTERNATOR
AND TO THE ALARM
BUZZER ENERGIZING IT IN
A PULSING MODE.
: DC VOLTMETER:
INDICATES THE AMOUNT THE
BATIERY IS BEING CHAflGED.
SHOULb SHOW 13V TO 14V.
AUTOMATIC ALARM SYSTEM
PREHEAT BUTION: WHEN DEPRESSED, IT CLOSES ·
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON
THE PREHEAT SOLENOID ALSO RECEIVES POWER AND
THIS IS TRANSMITIED TO THE ELECTRIC FUEL PUMP.
DC POWER IS ALSO TRANSMIITED TO THE START
BUTION.
.---',
11
: COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
REACHES 210° F (99°C), THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTION: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE
THIS BUTION WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUTION IS PRESSED AND HELD
AT THE SAME TIME.
5
OIL PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
FALL TO 10- 5 psi (0.7- OA kg/em'), THE SWITCH WILL CLOSE SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
SIGNAL.

CAPTAIN CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch, an RPM gauge, PREHEAT and START but-
tons, an INSTRUMENT TEST button and three indicator
lamps,
one for ALTERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
TEMPERATURE.
RPM GAUGE: REGISTERS REVOLUTIONS
PER MINUTE OF THE ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OF THE PANEL.
OIL PRESSURE ALTERNATOR
ALARM LIGHT ALARM LIGHT
WATER TEMPERATURE
ALARM LIGHT
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME
TIME.
6
The panel also includes an alann buzzer for low OIL
PRESSURE or high COOLANT TEMPERATURE. The
RPM gauge is illuminated when the KEY switch is turned on
and remains illuminated while the engine is in operation.
ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE FALLS
BELOW 10- 5 psi (0.7- 0.4 kg/em'). IN THIS EVENT, THE ALARM WILL EMIT A
PULSATING SIGNAL. THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
21 o•F (99°C). IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
PRESSURE REACHES 15 psi (1.1 kg/em'), THE ALARM WILL SILENCE.
TEST BUlTON: WHEN
PRESSED, TESTS THE
ALTERNATOR, THE OIL
PRESSURE, AND THE
COOLANT TEMPERA-
TURE CONTROL CIR-
CUITS. WHEN PRESSED,
THE ALTERNATOR, THE
OIL PRESSURE, AND
THE WATER TEMPERA-
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND-
ING THE ALARM
BUZZER.
~--.KFV SWITCH: THE KEY
SWITCH WHEN TURNED ON
SUPPLIES DC POWER TO THE
INSTRUMENT PANEL
CLUSTER, PREHEAT SWITCH,
EXCITATION TERMINAL OF THE
DC CHARGING ALTERNATOR
AND TO THE ALARM BUZZER
ENERGIZING IT IN A PULSING
MODE.
PREHEAT BUTTON: WHEN DEPRESSED, IT CLOSES
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON THE
PREHEAT SOLENOID ALSO RECEIVES POWER AND THIS IS
TRANSMITTED TO THE ELECTRIC FUEL PUMP. DC POWER
IS ALSO TRANSMITTED TO THE START BUTTON.

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements of NO. 2-D SAE 1313
and has a cetane rating
of #45 or higher. Grade of diesel fuel
according to
ASTM D975,
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your engine's fuel injection pump is very critical; invisible
dirt particles which might pass through the primary and
secondary titers can damage these finely machined parts.
It is
important to buy clean fuel and keep it clean. The best fuel
can
be rendered unsatisfactory by careless handling or
improper storage facilities. To assure that the fuel going into
the tank for your engine's daily use is clean and pure, the
following practice is advisable:
Purchase a well-known brand
of diesel fuel.The use of
additives to combat BACTERIAL growth in the fuel tank is
recommended such as Bio-Bor and an additive such as
Diesel Kleen +Centane Boost to help restore lubricity back
into the diesel fuel when an Ultra
Low Sulfur diesel is being
used.
Install and regularly service a good visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor 500 MA
or 230RMAM are goqd examples of
such filters. 10 MICRON FILTER
ELEMENT RECOMMENDED
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF,
CG-4, CH-4
or CI-4. Change the engine oil and filter after
the initial
50 hours of break-in operation. Then follow the
oil and filter change intervals as specified in the
MAINTENANCE SCHEDULE in this manual. Westerbeke
Corporatiin does not approve
or disapprove the use of
synthetic oils. If synthetic oils are used, engine break-in must
be performed using conventional oil. Oil change intervals
must
be as listed in the MAINTENANCE SCHEDULE
section of this manual and niot be extended if synthetic oils
are used.
NOTE: The information above supersedes all
previous startements regarding synthetic oil.
SAE OIL VISCOSITY
For all temperature ranges: SAE 15W-40 or SAE lOW-40.
Oil Pressure
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
55 psi (2.5 and 3.9 kg/cm2
).
NOTE: A newly started, cold engine can have an oil pressure
reading up to
60 psi (4.2 kglcm2 ). A warmed engine can have
an oil pressure reading as low as 25 psi (1.8 kglcm2 ). These
readings will vary depending upon the temperature
of the
engine, the load placed on the engine,
and the RPM's.
TRANSMISSION FLUID
Refer to the TRANSMISSION SECTION of this manual for
type
of fluid and quantity for each transmission model.
ENGINE COOLANT
Engine coolant is a 50/50 mixture of antifreeze and distilled
water. This coolant allows the engine to run at its proper
temperature by transferring heat from the engine to the
coolant. It also lubricates and protects the cooling system
from rust and corrosion. A
50150 mixture of antofreeze and
distilled water will protect the engine to 34° F (1.12° C).
PURCHASING ANTIFREEZE
Rather than preparing the mixture. Westerbeke recommends
buying the premixed antofreeze so that when adding coolant,
the mixture will always
be correct.
There are two common types
of antifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple), either can
be used
but do not mix the two and
if changing from one to another,
flush the engine thoroughly.
Premixed antifreeze for DIESEL Engines:
Specification #ASTM 5345
MAINTENANCE
Change the engine coolant every five years regardless of the
humber
of operating hours as the chemical additives that pro-
tect and lubricate the engine have a limited life.
Coolant Recovery Tank
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose of this recovery
tank is to allow for engine coolant expansion and contraction
during engine operation, without the loss
of coolant and
without introducing air into the cooling system. This kit is
provided and must
be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at
or above the level of the engine's manifold, but it
can be located below the level
of the engine's manifold if the
particular installation makes this necessary.
Engines & Generators
7

PREPARATIONS FOR INITIAL START -UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
0 Check the engine oil level. Add oil to maintain the level PLASTIC RECOVERY TANK
at the high mark on the dipstick.
D Turn on the fuel supply, then check the fuel supply and
examine the fuel filter/water separator bowl for contami-
CAP
nants.
D Check the transmission fluid level.
NOTE: Refer to the previous page for fuel, oil and
transmissionfluid.
D Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the positive
(+) battery cable is connected to the starter solenoid and
the negative(-) cable is connected to the engine ground
stud (this location
is tagged).
D Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: If the engine has notyet beenfilled with coolant,
refer to the COOLING SYSTEM section
of this manual.
D Visually examine the engine. Look for loose or missing
parts, disconnected wires, and unattached hoses. Check
the threaded connections and engine attachments.
D Make certain there is proper ventilation around the
engine. An ample supply is necessary for proper engine
performance.
D Make sure the mounting installation is secure.
D Ensure the propeller shaft is securely attached to the
transmission.
D Open the through-hull and prime the raw water intake
strainer. Inspect the raw water supply.
GLOW
CONNECTION
DIPSTICK~
8
~ .--\ APPROXIMATELY
\ONE QUART
\
~-
OIL
CAP

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
The models in this manual have a 12V DC electric starter
assisted by a DC air intake heater for both normal and cold
weather starting. The air heater heats the engine intake air,
providing a rapid start with less wear on the starter.
The start circuitry is designed so that the PREHEAT button
must be depressed for the time specified in the preheat chart.
Then, while keeping the PREHEAT button engaged, the
START button is depressed to crank the engine.
Starting Procedure
1. Place the transmission in neutral and advance the throttle
control to slightly open.
A CAUTION: Make certain the transmission is
in neutral. Starting in gear could result in serious
damage to your transmission, your boat, and
vessels nearby.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
3. Depress the PREHEAT button and hold it. The
instrument panel will energize. The alarm buzzer will
pulse and the electric fuel pump will energize. The
Preheat button should
be depressed in accordance with
the chart below:
Temperatu e/Preheat
Atmospheric Temperature Preheating Time
41 °F(5°C) or higher Approx. 10 seconds
41 °F(5°C) to 23°F (-5°C)
Approx. 15 seconds
23°F(-5°C) or lower Approx. 20 seconds
Limit of continuous use
30 seconds before cranking
NOTE: The START button will not energize unless the PRE-
HEATbutton is depressed. Depressing the PREHEATbutton
activates the glow plugs in the cylinder headso use the PRE-
HEATintermittently to avoid overheating the glow plugs.
4. While still depressing the PREHEAT button, depress the
START button. This will engage the starter solenoid.
When the engine starts, release the start switch and
preheat button. The pulsing alarm will silence once the
oil pressure reaches
5-l 0 psi.
NOTE: When starting:
A voltage drop will occur
when the preheat button
is depressed.
5. Should the engine not start when the START button is
depressed for 10 to 20 seconds, release both buttons and
wait 30 seconds; repeat the procedure above and preheat
longer. Never run the starterfor more than
30 seconds.
A CAUTION: Prolonged cranking intervals without
the engine starting can result in the engine exhaust
system filling with raw water. This may happen because
the pump is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
from happening by closing the raw water supply
through-hull shutoff, draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind.
6. Once the engine starts, check the instruments for proper
oil pressure and battery charging voltage.
NOTE: Never attempt to engage the starter while the
engine is running.
NOTE: Some unstable running may occur in a cold
engine. Depressing the PREHEATbutton
for 10-15
second intervals will help stabilize the engine rpm until
the engine operating temperature reaches 170
-190°F
(77- 88°C) and a propeller load is applied to the engine.
When the engine is running
and the PREHEATbutton is
depressed, a charging load on the
DC alternator will be
discernible.
Starting Under Cold Conditions
Make sure the lubricating oil is appropriate for the prevailing
temperature. Use oil with anAPI Specification
of CF or CG-4,
CH-4 or CI-4, SAE 15W-40 or IOW-40.
The battery should be fully charged to minimize voltage drop.
Use a sufficient amount of preheat to aid in starting. See the
Temperature/Preheat chart elsewhere in this section.
Stopping Procedure
To stop the engine, bring the throttle to an idle position and
place the transmission in neutral. Allow the engine to idle for
a few moments to stabilize temperatures. Tum the engine off
using the stop control cable.
If your engine is equipped with
an optional fuel shut off solenoid, tum offthe key switch at
the control panel.
NOTE: Make certain this key switch is in the OFF position
(12 o'clock).
If the key switch is left ON, the battery will
discharge.
An engine alarm buzzer is provided to warn the
operator
of this condition (key switch ON). The best method
of preventing the batteryfrom discharging is to remove the
key from the key switch after stopping the engine. ·
Engines & Generators
9

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS
The Captain Control Panel indicates alternator low discharge
with a red warning light.
The Admiral Control Panel uses a voltmeter to monitor the
performance
of the alternator.
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm
if the
coolant's operating temperature reaches approximately 210°F
(99°C).
AIR BLEED PETCOCK
COOLANT
TEMPERATURE
SWITCH
SENDORS
The coolant temperature and oil pressure sendors are not
installed in the engines as standard equipment. Both sendors
are, however, included in the Admiral Instrument Panel Kit.
These sendors (with connecting gauges) can be added as
accessories to either engine at any time and are easily
installed to the prewired engine.
10
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located off the engine's
oil gallery. This switch's sensor monitors the engine's oil
pressure. Should the engine's oil pressure fall to
10- 5 psi
(0.7- 0.4 kg/cm2 ), this switch will activate a pulsating alarm.
OIL PRESSURE SWITCH
/
/
/
ENGINE CIRCUIT BREAKER
SEND OR
The DC harness on the engine is protected by an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive current draw
or electrical overload anywhere in
the instrument panel wiring
or engine wiring will cause the
breaker to trip. In this event most engines will shut down
because the opened breaker disconnects the fuel supply.
If
this should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
engine.

ENGINE BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-
ated properly, a break-in time is required. The service life
of
your engine is dependent upon how the engine is operated
and serviced during its initial 50 hours
of use.
Breaking-in a new engine basically involves seating the pis-
ton rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored, which
is caused by overloading the engine during the
break-in period.
Your new engine requires approximately
50 hours of initial
conditioning operation to break in each moving part in order
to maximize the performance and service life
of the engine.
Perform this conditioning carefully, keeping in mind the fol-
lowing:
1. Start the engine according to the STARTING PROCE-
DURE section. Run the engine at fast idle while checking
that all systems (raw water pump, oil pressure, battery
charging) are functioning.
2. Allow the engine to warm up (preferably by running at
fast idle) until the water temperature gauge moves into
the
130- 140°F (55- 60°C) range.
11
3. While using the vessel, run the engine at various engine
speeds for the first
25 hours. Avoid prolonged periods of
idling.
4. Avoid rapid acceleration, especially with a cold engine.
5. Use caution not to overload the engine. The presence
of a
grey or black exhaust and the inability
of the engine to
reach its full rated speed are signs
of an overload.
6. During the next
25 hours, the engine may be operated at
varying engine speeds, with short runs at full rated rpm.
Avoid prolonged idling during this break-in period.
CHECK LIST
D Monitor the control panel gauges.
D Check for leaks of fuel and engine oil.
D Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
D Confirm exhaust smoke:
When the engine
is cold -white smoke.
When the engine is warm -almost smokeless.
When the engine
is overloaded -some black smoke and soot.
NOTE: See the TRANSMISSION section of this manualfor
break-in information on your transmission.

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your engine.
D Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
D Visually inspect the engine for fuel, oil, or water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the coolant recovery tank.
Periodically check the manifold coolant level.
D Check the transmission fluid level.
D Check your diesel fuel supply.
D Look for clean fuel in the fuel filter/water separator trans-
parent bowl.
D Check for loose wires at the alternator and make sure its
mounting is secure.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
D Check the raw water pump to make sure its mounting is
secure.
12
STARTING THE ENGINE
NOTE: See STARTING/STOPPING PROCEDURE in this
manual
for more detailed instructions.
1. Put the transmission in neutral, throttle advanced.
NOTE: Hydraulically operated transmissions have a
neutral safety switch through which the starter solenoid
energizing circuitpasses. This switch is open when the
transmission is in gear so the starter solenoid will not
energize.
2. Turn the KEY to the ON position (2 o'clock).
3. Depress PREHEAT (10 to 15 seconds).
4. While pressing PREHEAT, push START. As the engine
fires, release START.
5. Hold PREHEAT until the oil pressure reaches
15 psi
and/or the alarm shuts off.
NOTE: Some unstable running may occur in a cold
engine. This condition should abate as normal operating
temperature is reached
and loads are applied.
NOTE: Should the enginefail to start, wait 30 seconds,
then repeat the above procedure,
and PREHEATlonger.
6. Allow a few minutes for the engine to warm at a com-
fortable rpm (approximately 1000 rpm), then reduce the
rpm, and get underway.

MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hourmeter or
record your engine hours by running time.
NOTE: Many of the following maintenance procedures are
simple but others are more difficult and may require the
expert knowledge
of a service mechanic.
A WARNING: Never attempt to perform any service
while the engine is running. Wear the proper safety
equipment such as goggles and gloves, and use the
correct tools for each job. Disconnect the battery
terminals when servicing any of the engine's DC
electrical equipment.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE DESCRIPTION
MAINTENANCE
EACH
DAY
50 100
250
500 750 1000 1250
Fuel Supply
0
Diesel No. 2 rating of 45 cetane or higher.
Fuel/Water Separator
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
Engine Oil Level
0
Oil level should indicate between MAX. and LOW on
dipstick.
Coolant Level
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Transmission Fluid Level
0
Fluid level should indicate between MAX and LOW
on dipstick.
Drive Belts
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
0 NOTE: Keep engine surface clean. Dirt and
Check for fuel, oil and water leaks. Inspect wiring
oil will inhibit the engine's ability to remain
and electrical connections. Keep bolts & nuts tight.
cool.
Check for loose belt tension.
Fuel Filters (on engine)
0 0 0 0 0 0
Change at 50 hours then every 250 hours.
Starting Batteries
0
Check electrolyte levels every 50 operating hours
(and House Batteries) weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil and Filter
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hours, then
change both every 100 hours.
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Inspect zinc anode, replace if needed. Clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
0 0 0 0 0 0
Change filter every 200 hours.
Exhaust System
0 0 0 0
Initial check at 50 hours, then every 250 hours.
Inspect for leaks. Check anti-siphon valve opera-
tion. Check the exhaust elbow for carbon and/or
corrosion buildup on inside passages; clean and
replace as necessary. Check that all connections are
tight. Check casting integrity.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Throttle and Transmission
0 0 0 0
Check for loose fittings, cotter pins, etc.
Control Cable
Lubricate with WD-40 or equivalent.
Adjust Engine Idle Speed
0
800 -1200 rpm (depending on model). Adjust for
smoothest operation.
Raw Water Pump
0 0 0
Remove the pump cover and iimpeller. Inspect
impeller, cam, cover and wear plate. Replace as
needed. Check shaft for indications of support
bearing wear. Check for any shaft seal leaks and
repair as needed.
(continued)
13

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours
by running time.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE
EACH MAINTENANCE DESCRIPTION
DAY 50 100 250
500 750 1000 1250
Coolant System
D D
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
DC Alternator
D D D
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Transmission Oil Cooler
D
Remove; have professionally cleaned and pressure
tested.
Engine Transmission
D
Chattering at idle and low rpms is an indication
Damper Plate
of damper plate wear. Remove and replace.
*Fuel Injectors
D
Check and adjust injection opening pressure and
spray condition.
*Starter Motor
D D
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
*Preheat Circuit
D D
Check operation of preheat solenoid. Remove and
clean glow plugs. Reinstall with anti-seize
compound on threads.
*Engine Cylinder
D D
Check compression pressure and timing (see Engine
Compression Adjustments).
*Adjust the Valve Clearances
D D D
Adjust Valve Clearances (see ENGINE
ADJUSTMENTS).
*Heat Exchanger
D
Remove, have professionally cleaned and pressure
tested.
Lubricate Panel Key Switch
D D D D D D
At first 100 hours, then each year at winterizing.
with "Lockeze"
Transmission Fluid
D D D D D D
Initial fluid change at 25 hours, then every
300 hours or at winterizing.
Raw Water Pump Drive
D D
Remove raw water pump and inspect the pump's
shaft end and the slotted drive gear for wear.
Replace components as needed.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines &Generators
14