Westerbeke 44A FOUR-35 C THREE User manual

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OPERATORS MANUAL
FOR THE
44A FOUR - 35C THREE
AND THE
448 FOUR -350 THREE
MARINE DIESEL ENGINES
PUBLICATION NO. 44180
2nd Edition I October 2001
WESTERBEKE CORPORA TION • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
AII'Il M.mberNali01llll MIlI'iM M(IIIufOClu,..,.. Ar.ociDlion

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 byfailure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, yourpersonnel,
and your machinery.
The following safety instructions are in compliance with
theAmerican Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 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: 00 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.
Engines & Generators

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.
BATTERY 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 tenninals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
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 infonnation refer to ABYC T-22 (educa-
tional infonnation 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 Dr 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-l 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 willresult 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 available from your WESTERBEKE
dealer.
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 ..................................... 31
Captains Panel ...............................................6
Tachometer ........................................................ 33
Diesel Fuel, Engine Oil and Engine Coolant.. ..... 7
Engine Adjustments . .......................................... 34
Oil Pressure ...................................................7 Testing Engine Compression.......................35
Preparations for Initial Start-Up . ........................ 8
Starting/Stopping Procedure ............................... 9
Warning Lights, Alarms and Circuit Breaker .... 10
Engine Break-in Procedure .. ............................. 11
The Daily Operation .......................................... .12
RPM's Guide ...............................................12
Fuel Injectors ...............................................35
Valve Adjustments .......................................36
J.S. and B.W. Transmission .............................. 37
Borg Warner Velvet Drive Transmission ........... 39
Hurth HBW Transmission .................................. .42
PRM Newage Transmissions ... ........................ ..45
Maintenance Schedule ..................................... 13
Transmission Troubleshooting ......................... .47
Cooling System .................................................. 15
Propeller Recommendation Chart.. ................. ..48
Thermostat................................................... 16
L U dR···
ay- p an ecommlsslonmg .......................... .49
Raw WaterPump .......................................... 16
Heat Exchanger ........................................... 17
Air Intake/Silencer....................................... 18
Fuel System ..... ; ................................................. 19
Fuel Lift Pump............................................. 19
Fuel Filters................................................... 19
44 Four Engine Specifications ......................... .51
35 Three Engine Specifications ........................ 52
44 Four and 35 Three Torque Specifications ... 53
Standard Hardware ........ .................................... 54
Sealants & Lubricants ....................................... 54
. Fuel Water Separator.....:............................. 16
Standard and Metric Conversion Data ............. 55
Clow Plugs...................................................20
Engine Lubricating Oil ...... ................................. 21
Oil Change................................................... 21
Oil Pressure .................................................22
Suggested Spare Parts ...................................... 56
Spare Parts Kits ................................................. 56
European Maritime Council Registration ......... 57
Remote Oil Filter.........................................23
Engines & Generators
1

PARTS IDENTIFICATION 44A FOUR/35C THREE
WATER INJECTED
EXHAUST ELBOW
20ACIRCUIT
BREAKER
REAR
\
ZINC
ANODE OIL FILTER
COOLANT PRESSURE CAP
OIL COOLER
THERMOSTAT
ASSEMBLY
WATER HEATER
CONNECTION
FRONT
SIDE OIL FILL
RIGHT SIDE
AIR INTAKE/AIR FILTER
OIL FILL
FRONT
PREHEAT SOLENOID
DC ALTERNATOR
FUEL FILTER
RAW WATER PUMP
REAR
UNIT I.D. PLATE
START MOTOR
LEFT SIDE
ATFDRAIN
Engines & Generators

INTRODUCTION
This WESTERBEKE Diesel Engine is a product of
WESTERBEKE's
long years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour 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 WESTERBEKE Warranty 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
'~/WESTERBEKE
,
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 ofa 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 SOFIWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITHRESPECT
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 SOFIWARE.
WESTERBEKE customers should keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence ofearlier 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 ofWESTERBEKE 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 ofyour 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 number and serial number are located on
a nameplate mounted on the side
of the engine's manifold.
The engine's serial number can also be found stamped into
the engine block
just above the injection pump. Take the time
to enter this information on the illustration
of the nameplate
shown below, as this will provide a quick reference when
seeking technical information and/or ordering repair parts.
C2¥ii4il :143i
o .. 0
• MODEL SPEC AVO. 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.
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.
Engines & Generators
4

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
1110 hours. The panel also includes a WA1ER 1EMPER-
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 OFTHE 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(n·- 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 pOVl:'er 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 kglcm
2
).
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').
__ -1\,,, SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER.
PREHEAT PRESSED, ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL liFT PUMP, THE
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS
BUTTON ENERGIZES THE START BUTTON.
..
DC VOLTMETER:
INDICATES THE AMOUNT THE
.BATTERY IS BEING CHARGED.
SHOULb SHOW 13V TO 14V.
~
~
AUTOMATIC ALARM SYSTEM
,•
•. COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
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.
~ : SUPPliED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
.. ,': REACHES 210· F (gg·C), THIS SWITCH WILL CLOSE SOUNDING THE
. -.- ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
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 5 -10 psi (0.4 - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
SIGNAL.
Engines.& Generators
'5

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 1ESTbutton and three indicator
lamps,
one for ALlERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
lEMPERATURE.
RPM GAUGE: REGISTERS REVOLUTIONS
PER MINUTE OF THE ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OF THE PANEL.
WATER TEMPERJlTI
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.
The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT lEMPERATURE. 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 IFTHE ENGINE'S OIL PRESSURE FALLS
BELOW 5 -10 psi (0.4 - 0.7 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
210°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 BUTTON: 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.
~--- KEY SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER.
PREHEAT BUTTON: WHEN PRESSED, ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL
SOLENOID ON THE INJECTION PUMp, AND THE ENGINE'S
GLOW PLUGS, AND BYPASSES THE ENGINE'S OIL PRES-
SURE ALARM SWITCH. IN ADDITION, THIS BUTTON ENER-
GIZES THE START BUTTON.
Engines,&Generators
·6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (ASTM), and has a cetane rating
of#45 or better.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump is very critical; invisible dirt par-
ticles which might pass through the filter can damage these
finely finished 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 fuel.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
. The Raycor500
FG or 900 FG are good examples of such
filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50
hours of break-in operation, and every 100 hours of operation
thereafter. For recommended oil viscosity, see the following
chart:
Operating Temperature
Oil Viscosity
Above 68°F (20°C)
SAE 30, 10W-30 or 15W-40
41° - 68°F (5 - 20°C)
SAE 20, 10W-30 or 15W-40
Below 41°F (5°C)
SAE 10W-30 or 15W-40
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
nonnal operation, the oil pressure will range between 35 and
55 psi (2.5 and 3.9 kglcm2
).
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
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze perfonns double duty. It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically bal-
anced, crucial to long tenn protection.
The distilled water and antifreeze should
be premixed before
being poured into the cooling circuit.
NOTE: Lookfor the new environmentally-friendly long lasting
antifreeze that is now available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial to the engine's cooling system. They
retard rust and add to the life
of the circulating pump seal.
ANTIFREEZE PROTECTION
Antifreeze Concentration 23% 30% 35% 50%
Freezing Temperature 14°F 8°F -4°F -40°F
(-10°C) (-13°C) (-20°C) (-40°C)
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 orabove
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
PREST ART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
D 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: Referto the previous page for fue~ 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 :.'\Il>'~~
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 not yet beenfilled with coolant,
refer to the COOLING SYSTEMsection
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.
Engines & Generators
8
OIL FILL CAP

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
The 44N35Cdiesel engine has a 12V DC electric 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 switch. The voltrrieter, panel
lights, gauges, meters and fuel solenoid will be activated.
The PREHEAT switch should be depressed in accor-
dance with the following chart:
TemperatureJPreheat
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 STARTbutton will not energize unless the PRE-
HEATbutton is depressed. Depressing the PREHEATbutton
activates the glow plugs in the cylinder head so use the PRE-
HEAT intermittently to avoid overheating the glow plugs.
4. While still depressing the PREHEAT button, depress the
START button. This will engage the starter solenoid.
Upon engine starting, release the START switch. Do not
release the PREHEAT switch until the oil pressure reaches
5 - 10 psi. Then as long as the high water temperature and
low oil pressure protective circuits do not activate, the engine
will remain energized and continue to run.
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 starter for 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 an API Specification
of CF or CG-4,
SAE 30, lOW-30, or 15W-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. Turn the engine off
using the stop control cable.
If your engine is equipped with
an optional fuel shut off solenoid, turn off the key switch at
the control panel.
NOTE: Make certain this key switch is in the OFFposition
(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.
TheAdmiral 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 2100P
(99°C). .
COOLANT
TEMPERATURE
SWITCH
SENDORS
The coolant temperature and oil pressure sendors are not
installed in the 44N35C 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.
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located offthe engine's
oil gallery. This switch's sensor monitors the engine's oil
pressure. Should the engine's oil pressure fall to 5 - 10 psi
(0.4 -0.7 kg/cm2), this switch will activate a pulsating alarm.
DlL PRESSURE SWITCH
/
/
ENGINE CIRCUIT BREAKER
SENDOR
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.
Engines & Generators
10

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 -1400P (55 -60°C) range.
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.
S. 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
o Monitor the control panel gauges.
o Check for leaks of fuel and engine oil.
o Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
o 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.
Engines & Generators
11

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your engine.
D Record the hounneter 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.
STARTING THE ENGINE
NOTE: See STARTING/STOPPING PROCEDURE in this
manualfor 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. Tum 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.
S. 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 engine fail to start, wait 30 seconds,
then repeat the above procedure, and PREHEAT longer.
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.
Engines &Generators
12

MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hourrneter 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
Fuel/Water Separator
0
Engine Oil level 0
Coolant level
0
Transmission Fluid level
0
Drive Belts
0
weekly
Visual Inspection of Engine
0
NOTE: Keep engine surface clean. Dirt and
oil will inhibit the engine's ability to remain
cool.
Fuel Filter
0 0 0 0 0 0
Starting Batteries
0
(and House Batteries)
weekly
Engine Oil and Filter
0 0 0 0 0 0 0
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
Fuel/Water Separator
0 0 0 0 0 0
Exhaust System
0 0 0 0
Engine Hoses
0 0 0 0 0 0
Throttle and Transmission
0 0 0 0
Control Cable
Adjust Engine Idle Speed
0
Raw Water Pump
0 0 0
Engines & Generators
13
Diesel No.2 rating of 45 cetane or higher.
Check for water and dirt in fuel (drain/replace filter
if necessary).
Oil level should indicate between MAX. and LOW on
dipstick.
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Fluid level should indicate between MAX and LOW
on dipstick.
Inspect for proper tension (3/8" to 1/2" deflection)
and adjust if needed. Check belt edges for wear.
Check for fuel, oil and water leaks. Inspect wiring
and electrical connections. Keep bolts & nuts tight.
Check for loose belt tension.
Change at 50 hours then every 250 hours.
Check electrolyte levels every 50 operating hours
and make sure connections are very tight. Clean off
excessive corrosion.
Initial engine oil & filter change at 50 hours, then
change both every 100 hours.
Inspect zinc anode, replace if needed. Clear the heat
exchanger end of zinc anode debris.
Change filter every 200 hours.
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
tig ht. Check casti ng integ rity.
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Check for loose fittings, cotter pins, etc.
Lubricate with WD-40 or equivalent.
Adjust to 750 - 1000 rpm
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate when reassembling.
(continued)
--+

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 appro-
priate antifreeze mix.
DC Alternator
D D D
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Air Intake Filter
D D D D D D
Clean every 100 operating hours.
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.
*Fuellnjectors
D
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
*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
D D D D D D
Initial fluid change at 25 hours. then every
Fluid
300 hours or at winterizing.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines &Generators
14