Westerbeke 44A FOUR - 35C THREE User manual

- PUBLICATION NO. 044180 ·
..
REVISION 4 ' APRIL 2015
WE:STE:RBE:KE CORPORATION• 150 JOHN HANCOCK ROAD
MYLES STANDISHINDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
N.,.M•mh., National MCJJ"iM Manufactunm Association
a LV

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
• Throbbing in Temples
•Nausea
•Headache
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU DR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical anentio.n. Shut down the unit and do not restart
until it has been inspected and repaired.
WARNING
Genera1D1s PrtxiJce!CAABON MONOXIDE
Regular Maintenance AecJ,lired
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or genet;~tor.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are .Inexpensive and easily
obtainable at your local marine store.
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.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your
personne~ andyour mac;hinery.
The following safety instructions,are in compliance with
tire American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine Is running. Lethal voltage Is present at
these connections!
• Do not operate this machinery without electrical
enclosures and cov~rs in place.
• Shut off electrical 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.
PREVENT BURNS -HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
. veryhotl
• Monitor engine antifreeze coolantlevel at the. plastic
coolant recovery tank and periodicaly at th~ filler cap
location .on the water jacketed exhaust manifold, but only
when the engine is COLD.
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 fuel injector, fuel line, filter, fuel
pump; or other potential sources of spilled fuel or fuel
vapors. Use a suitable container tQ catch all fuel when
._removing the fuel lines or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smol{e orpermit flames or sparks to occur near
the fuel system. ;K~p the compartment and the
engine clean and free of debris to minimize the
chances of fire. WiPe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
Injury or detft"!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor oefore running
the blower. Run the engine compartment blower prior to
starting, follow the recommendation of the vessel builder.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area away from
spark-produCing
.equipment and out of the reach ofchildren.
• Do not fill the fuel tank(s) while the ,engine while it 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
servicing. 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 ofleaks.
• 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
• To prevent accidential starting when servicing the genera-
tor, tum OFF the DC breaker or remove the fuse
from the generators control panel.
• To prevent accidential starting ofthe generatpr,,. .
when servicing, turn the battery selector switch 'to the
OFF position.
• Make certain all personnel are dear of the engine before
starting.
• Make certain all covers, guards, and hatchC?S 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
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases orfuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive 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 tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
A WARNING: Accidental starting can cause Injury
or death/
BAnERYACID
A WARNING: Sulfuric acid In batteries can cau$e
severe Injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. Ifit comes in contact with your slQn, 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/water-injected elbow
is securely attached.
• Be sure the unit and its SUI'I9undings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder ordealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO} Is an Invisible
odorless gas. Inhalation produces nu-1/ke symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. 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, yents, 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.
IIi 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
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause Injury
or death!
• Do not service the engine while it is running. Ifa
situation arises in which itis absolutely
necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; 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.
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 AND GENERATOR INSTALLATIONS
Preparations to install an f?ngine 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-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your UNIVERSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis,.MD 21403
( 410) 990-4460
www.abycinc.org
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CPR 33 AND CFR46"
Code ofFederal Regulations
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 infonnation: · ·.
CODES AND REGULATIONS
Strict federal reguiations, ABYC guidelines, and safety cod~ mu_st 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 waterlirie, proVision& inust 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 exhaust manifold injection port is at or below the load waterline willresult in
mw water damage to the engine andpossibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaustelbow relative
to the vessel's waterline under the vessel's various operating conditions~ instaU a
siphon-br~alc.
,.
NOTE: A siphon-break requ{n~s periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine di:inuige.' Consult the siphon-break manufacturer for proper maintenance.
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
EXHAUST SYSTEM
SIPHON-BREAI{ W/71{ STAINLESS
LOOP'
The exhaustsystem's hose Musrbe certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use of this type ofhose allows for extreme bends_
and turns without the rteed of additional fitting and clamps to accomplish these bends
and turns. In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed-to prevent the entry of water-into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel, ·
engines and generators, Is supplied with each unit. A pdf is available
to download from our website at 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 Locations................................. .4 Battery ............................................................26
Control Panels .....................................................5 Wiring Diagrams/Schematics.........................27
Admirals Panel.................................................
5
Engine li'oubleshootlng ...................................... .29
Captains Panel..................................................6
Tachonleter ............................................................ 31
Diesel Fuel, Engine 011 and Engine Coolant ....... 7
Engine Adjustments ............................................ .32
Oil Pressure ..................................................·....7 Idle Speed.......................................................32
Preparations for lnHial Start-Up .........................8
Starting/Stopping
Procedure ..............................9
Warning Lights, Alarms and Circuit Breaker ... 10
Engine Break-In Procedure ............................... ll
The Dally Operation ........................................... 12
Maintenance Schedule ..................................... 13
Drive Belt Tension......................................... .32
RPM Chart......................................................32
Fuel Solenoid (optional).................................32
Valve Clearance/Timing ................................
.33
44 Four Engine Specifications ........................... 34
35 Three Engine Specifications ...................... 34A
J.S. and B.W. Transmission ................................. 35
Cooling System .................................................. 15
Thermostat...................................................... 16
Raw Water Pump............................................ 16
Heat Exchanger .............................................. 17
Air Intake/Silencer.......................................... 18
Borg Warner Velvet Drive Transmission ............ 37
ZF Transmissions .................................................. 40
Borg Warner lransmisslons ............................... .43
Transmission lroublesbootlng ............................ 45
Fuel System ....................................................... 19
Propeller Recommendation Chart ...................... 46
Fuel Lift Pump................................................ 19
Lay-Up and Recommissioning ........................... .4 7
Fuel Filters...................................................... l9
44 Four and 35 Three Torque Specifications .. .49
Fuel Water Separator...................................... 19
Standard Hardware .............................................. 50
Glow Plugs/Fuel Injectors..............................20
Sealants and Lubricants ..................................... 50
Engine Lubricating 011 ....................................... 21
Oil Change...................................................... 21
Oil Pressure .................................................... 22
Standard and Metric Conversion Data .............. 51
Suggested Spare Parts ........................................ 50
Remote Oil Filter............................................23
Engines & Generators
1

PARTS IDENTIFICATION
WATER INJECTED
EXHAUST ELBOW
20ACIRCUIT
BREAKER.
REAR
FRONT
DC ALTERNATOR
RAW WATER PUMP
RIGHT SIDE
OIL FILL
UNIT I.D. PLATE
START MOTOR
2
COOLANT PRESSURE CAP
OIL FILTER'
OIL COOLER
AIR_ INTAKE/AIR FILTER
WATER HEATER
CONNECTION ·
FRONT
SIDE OIL FILL
FUEL LIFT PUMP
REAR

INTRODUCTION
This WESTERBEKE Engine is a product of
WESTERBEKE'S long
years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable perfonnance 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
manual carefully and observe all the safety precautions
throughout Should
your engine require servicing, contact
your nearest WESTERBEKE dealer fQr.assistance.
This is your Operators Manual. AService Manual will also
be available fi'om your WESTERBEKE dealer. If you are
planning to install this equipment contact yourself, contact
your WESTERBEKE dealer for WESTERBEKE'S
Installation
Manual.
Customer Identification Card
Customer Identification
WESTERBEKEO~R ____________ _
MAlNSTREET
____________________ __
HOMETOWN, USA _________ _
Model
Ser. # ____ _
Expires--------------''--·
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Policy Statement is included
in the product documentation package. There is a mail in
warranty registeration card that you can fill out and mail in to
register your warranty or go to our website www. wester-
beke.com
and register your product's warranty online. You
should receive a Customer Warranty Registeration Card in
the mail within 60 days ofregistering. Ifyou do not. please
contact the
factory via [email protected] advising of this
and providing your name, unit model, serial number and date
unit was put into service.
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures
and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE customers should also keep
in mind the time
span between printings ofWESTERBEKE product
software
and the unavoidable existence ofearlier
WESTERBEKE manuals. In summation, product
software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied upon exclusively 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 ofyour marine
engine, critical infonnation 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 p;operly followed,
can result in personal injury or loss of life.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing have
resulted in aWESTERBEKE engine capable of many thousands
of hours ofdependable service. However, the manufacturer can-
not control how or where the engine is installed in the vessel or
the manner in which the unit is operated and serviced in the field.
This is up to the buyer/owner-operator.
NOTE: Six important steps to ensure a long engine/generator life.
• Proper engine installation.
• An efficient, well-designed exhaust system that includes an
anti-syphon break to prevent water from entering the engine.
• Changing the engine oil every 250 operating hours.
• Proper maintenance of all engine components according to the
maintenance schedule in this manual.
• Use clean, filtered diesel fuel.
• Winterize your engine according to the LAY-UP AN.D
RECOMMISSIONING section in this manual.
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-offlever. 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.
~2£ii#;l=143=t
0 . . 0
• MODEL SPEC AVO• "'"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.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters.
Carbon monoxide,
even in small amounts, is deadly. ·
The presence of carbon monoxide indicated an exhaust leak
from the engine or generator
or from the exhaust
elbow/exhaust hose,
or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
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.
INSTALLATION MANUAL
Publication #43400 provides detailed infoimation for
installing generators.
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 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"-BB"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 po~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
-~lectrical 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/cm
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').
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:
AUTOMATIC ALARM SYSTEM
INDICATES THE AMOUNT THE
.BATTERY IS BEING CHARGED.
SHOULb SHOW 13V TO 14V.
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 TRANSMITIED TO THE ELECTRIC FUEL PUMP. ·
DC POWER IS ALSO TRANSMITIED TO THE START
BUTTON.
~"'h SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
o/1. ··. ___ , •• ·' COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
REACHES 210" F (99"C), THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
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.
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- 0.4 kg/em'), THE SWITCH WILL, OPEIN 'SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PIJ[SATING
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 1EST button and three indicator
lamps, one for AL1ERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
1EMPERATURE.
RPM GAUGE: REGISTERS REVOLUTIONS
PER MINUTE OF THE-ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OF THE PANEL.
OIL PRESSURE
ALARM
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.
The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT 1EMPERATURE. The
RPM gauge is illuminated when the KEY switch is turned on
and remains illuminated while the engine is in operation.
ALARM: THE ALARM'WILlSOUND'IF THE ENGINE'S OIL PRESSURE FALLS
BELOW 10- 5 psi (0;7..:. 0.4 kg/em'). IN THIS EVENr;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 ALARMWILL·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: 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.
Engines.& Generators
.6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER.
(No. 2-D (SAE J313) diesel fuel according to ASTM 0975).
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
particles 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
i~ clean and pure, the following practice is
advisable:
Purchase a well-known brand
of fuel.lnstall and regularly
service a good, visual-type fuel filter/water separator between
the fuel tank and the engine. The Raycor 500
MA or 230
RMAM are good 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 an
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 Corporation does
not approve or disapprove of the use of synthetic oils. If
synthetic oils are used, engine break-in must be petformed
using conventional oil. Oil change intervals must be as in the
MAINTENANCE SCHEDULE, not extended because
synthetic oils are used.
SAE OIL VISCOSITY GRADES
For all temperatures use SAE 10W-40 or 15W-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
C?il pressure will range between 35 and
65 psi 2.5 and 3.9 kg/cm2 ).
NOTE: A newly started, cold engine can have an oil pressure
reading upwards of 60 psi (4.2 kg/cm2l. A warmed engine can
have an oil pressure reading as low as 25 psi (1.8 kg/cm2l.
T7zese 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 performs 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
balanced, crucial to long term protection.
The distilled water and antifreeze should
be premixed before
being poured into the cooling circuit.
PURCHASING ANTIFREEZE
Select a brand of antifreeze specified for diesel engines.
Antifreeze·specified for diesel engines contain a special
additive to protect against cavitation erosion
ofthe engine's
cylinder walls. Prestohe and Zerex are two nationally known
brands that offer antifreeze specifically for use in diesel
engines. Select the pre-mix variety so that the correct
mixture will always
be added to the cooling system when
needed. Change.the antifreeze mixture according to the
MAINTENANCE SCHEDULE in this manual.
MAINTENANCE
Change the engine coolant every five years regardless of the
number
of operating hours as the chemical additives that
protect and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
engine
or generator. The purpose of this recovery tank is to
allow for engine coolant expansion and contraction during
engine operation, without the loss
of coolant and withoi.1t
introducing air into the cooling system. This kit is provided
and must
be installed before operating the engine.
Engines & Generators
7

PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
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-
nants.
D Check the transmission fluidlevel.
NOTE: Refer to the previous pageforfuel, oil and
transmission fluid. ·
D Check the DC electrical system. Inspect wire coiJnections
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 ~~¥~iii!~~>...
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 COOUNG 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.
SIDE OIL FILL CAP
DIPSTICK~ , ~
~ . APPROXIMATELY
pNEO~ART
OIL LEVEL
~
Engines & Generators
8
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.~/Preheat
Atmospheric Temperature
Preheating nme
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-
HEAT button 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.
When the engine starts, release the start switch and
preheat button.
The pulsing alarm will silence once the
oil pressure reaches 5-10 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
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 PREHEAT button 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,
CH-4 orCI-4, SAE lSW-40 or 10W-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, turn off the 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.
TheAdmiral Control Panel uses a voltmeter to monitor the
performance
of the alternator.
COOLANT TEMPERATURE SWITCH
A coolant tempemture switch is located on the thermostat
housing. This switch will
activa~ a continuous alarm if the
coolant's operating temperature reaches approximately 210°F
(99°C).
AIR BLEED
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 con.necting 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 10-5 psi
(0.7- 0.4 kg/cm2 ), this switch will activate a pulsating alarm.
OIL PRESSURE SWITCH
/
/
/
ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by an engine-
mounted manual reset circuit breaker
(20 amps DC).
Excessive current dmw 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.
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- 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.
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 circuit passes.
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.
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 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
rpro, and get underway.
Engines &Generators
12

MAINTENANCE SCHEDULE
WARNING: Never attempt to peitorm 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. When servicing/replacing DC components, ensure the key switch In the instrument
pane/Isin the OFF position or turn OFF the DC starting battery.
NOTE: Use the engine hourmetergauge to log your engine hours or record your engine hours running time.
INSPECTION AND PREPARATION FOR INITIAL START-UP (Also refer to the PREPARATIONS for START-UP in the manual).
Coolant Level
Engine Oil Level
Fuel FilterJWater Separator (owner installed)
Fuel Supply
*Visual Inspection of Engine
Transmission Fluid Level
Drive Belts
AFTER THE FIRST 50 HOURS OF OPERATION
*Inlet Fuel Filter
*Fuel Filter and "0" Rings
Engine Oil and Filter
*Exhaust System
Engine Idle Speed
Transmission Fluid
Heat Exchanger
EVERY 50 OPERAY.ING HOURS OR MONTHLY
*Drive Belts
(Fresh Water/Raw Water Pumps as applicable) ·
Starting Batteries
Electric Fuel Pump
Raw Water Pump
EVERY 100 OPERATING HOURS OR YEARLY
Air Intake Filter
Heat Exchanger
Panel Key Switch
*Drive Belts
(Fresh Water/Raw Water Pumps as applicable)
Starting Batteries
Electric Fuel Pump
Raw Water Pump
Throttle and Transmission Cables
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
The fuel in the filter should be clean and the valves open. Replace filter every 250 operating
hours or once a year.
Fuel tank must have the proper amount of clean diesel fuel and the fuel valve must be open.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed. ·
Fluid level should be at the top mark on the dipstick.
Inspect for proper tension (3/8' to 112' deflection) and adjust if needed.
Initial change, then every 250 hours or once a year.
Initial change, then every 250 hours or once a year.
Initial engine oil and filter change at 50 hours, then change both every 250 hours.
Initial check at 50 hours. then every 250 hours or once a year. Carefully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check the integrity/mounting security of the water injected exhaust elbow.
Adjust as needed. (Ref. page #32).
Initial change, then at 300 hours or once a season.
Open end caps and clean out debris. Change zinc anode if necessary. Determine zinc service
interval for your area.
Inspect for proper tension (3/8' to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for gorrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect impeller, check drive shaft security. Inspect there is no shaft water or oil seal leaks.
Remove and clean filter, replace if contaminated.
Inspect and clean zinc anode. Note the condition, then determine your own schedule. If zinc
anode needs replacing, yoll should remove the end cap and clean out the debris.
Replace zinc if necessary.
Lubricate with "lockeze".
Inspect for proper tension (3/8' to 1/2' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect impeller, check drive shaft security. Inspect there is no shaft water or oil seal leaks.
Check security of cables to brackets. Lubricate cables.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
Engines & Generators
13

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your engine hours running time.
EVERY 250 OPERATING HOURS OR YEARLY
Transmission
Engine Oil
Fuel Filter and 0-Rings
Inlet Fuel Filter
Air Intake Filter
DC Alternator
Electric Fuel Pump
*Vibration Isolators/Engine Mounts
Heat Exchanger
*Exhaust Elbow/Exhaust System
EVERY 500 OPERATING HOURS OR FIVE YEARS
*Fuel Injectors
Coolant System
*Valve Clearances
*Starter Motor
Raw Water Pump
*Preheat Circuit
*Engine/Shaft Alignment
EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS
*Heat Exchanger
*Adjusting the Valve Clearances
*Positive Crankcase Ventilation Valve
*Fuel Injectors
*Transmission Oil Cooler
*Transmission Damper Plate
Change Change fluid at 300 operating hours. Lubricate control cable and check attachment.
Change the engine oil and oil filter (always together)
Remove and replace fuel filter and all sealing 0-rings.
Remove and replace inlet fuel filter.
Remove and clean, replace if contaminated.
Check mounting bracket, tighten electrical connections.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Check vibration isolators, brackets and mounting hardware. Replace as needed.
Inspect zinc anode replace if necessary.
Check the structural integrity of the water injected exhaust elbow casting. Check the integrity
of the exhaust system attached to the elbow. All hose connections should be secure. No
chaffing. No exhaust leaks. Hoses and muffler are in good serviceable condition.
NOTE: An exhaust leak will cause exposure to diesel exhaust!
Check and adjust injection opening pressure and spray conditions.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Replace the
thermostat and cooling pressure cap.
Adjust valves. (Incorrect valve clearance will result in poor engine performance)
Che.ck solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
Inspect impeller, check drive shaft security. Inspect there is no shaft water or oil seal leaks.
Check operation of the pre-heat. Remove and clean the glow plugs. Re-install with anti-seize
compounds on threads.
Check security of the shaft coupling and check shaft alignment.
Remove the heat exchanger for professional cleaning and pressure testing. Change the
antifreeze and flush the system.
Adjust the valves.
Disassemble and clean.
Pressure test injectors/re-build at 1500 hours.
Remove, inspect casting, clean and replace as needed.
Inspect the damper plate, replace if necessary (damper plate chatter at idle speed is an
indication of damper spring wear).
WARNING: Never attempt to perform any service while the unit is operating. Wear the proper safety equipment such as goggles
and gloves, and use the correct tools for each type of maintenance performed. Shut OFF the control panel's DC breaker when
servicing any of the engines DC electrical components. ·
NOTE: Keep the engine surface clean. Dirt and oil will inhibit the engine's ability to remain cool.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.